Home | Register Login | Wanted Manuals | MarketPlace | Members Area | Manuals Manufacturer Directory | UPC Lookup | Information Pages | Policy


Back to Riello Manuals Page       Model: 40 Series F5 Riello Burners Residential Oil Burner w Electronic Air Shutter
Regular Text Search or Search by Model Number

Register / log-in to add to your Hammerwall Collection.
Manual Location


This is a partial text extraction from the pdf, to download the pdf, click the Manual tab. If you want to search this text, hold control and F, and type the word you are looking for.

Page: 1

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
Page: 2

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 ( carton ) QTY . DESCRIPTION ( parts bag ) Burner chassis with cover 2 - Mounting flange bolts ( short ) 1 - 2 - Semi - flange bolts ( long ) 1 - Universal Mounting Flange 4 - Nuts 2 - Semi - flanges 2 - Chrome nuts 1 - Mounting gasket Installation Manual 1 - Oil pump connector ( supply ) 1 - 1 - Oil pump connector ( return ) 1 - By - pass plug 1 - Female ¼ " NPT adapter 1 - Male 3 / 8 " NPT adapter _ ' ( Separate carton ) 1 - Combustion Head 1 - 2.5 n _ n Allen key * OEM burners shipped with combustion head mounted Standard 40 F3 - F5 I - O manual Rev4 l . doc Page 2 of 2
Page: 3

RIELLO 40 F3 TECHNICAL DATA B E Im II I _ , E1 O " ' Z ] ( < ) A C 1 l 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 : NO heavier than # 2 FUEL OIL FIRING RATE : 0.50 to 0.95 US GPH EFFECTIVE OUTPUT : 70,000 to 133,000 BTU / h 120V 60Hz ( + 10 % - 15 % ) VOLTAGE ( Single Phase ) : ABSORBED ELECTRICAL POWER : 155 Watts MOTOR ( rated ) : 3250 rpln Run Current 2.2 AMP CAPACITOR : 12.5 Microfiarads PUMP PRES SURE : 130 to 200 psig PRIMARY CONTROL : RIELLO 530 SE / C IGNITION TRANSFORMER : 8Kv 16mA 60 ° _ _ B ou A MOUNTING FLANGE DIMENSIONS ' _ _ _ _ , _ , , I / _ _ \ K # _ . , \ 1 MODEL F3 A B C D / / 7 / / i " , ' , _ , . . ! o _ Inch 1 1 / 4 1 / 4 7 / 16 2 3 / 16 - ( - _ - . . . . ! . . - . . . . . - . _ . - } _ - . £ lnm 32 6 11 56 i : s Standard 40 F3 - F5 I - O manual Rev4 l . doc Page 3 of 3
Page: 4

RIELLO 40 F5 TECHNICAL DATA B E Im II I _ , E1 O " ' Z ] ( < ) A C 1 l 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 : NO heavier than # 2 FUEL OIL FIRING RATE : 0.75 to 1.65 US GPH EFFECTIVE OUTPUT : 105,000 to 231,000 BTU / h 120V 60Hz ( + 10 % - 15 % ) VOLTAGE ( Single Phase ) : ABSORBED ELECTRICAL POWER : 175 Watts MOTOR ( rated ) : 3250 rpln - 2.2 AMP CAPACITOR : 12.5 MicroFarads PUMP PRES SURE : 130 to 200 psig PRIMARY CONTROL : RIELLO 530 SE / C IGNITION TRANSFORMER : 8Kv 16mA 60 ° _ _ B ou A MOUNTING FLANGE DIMENSIONS ' _ _ _ _ , _ , . I / _ _ \ K # _ . , \ 1 MODEL F5 A B C D / / 7 / / i " , ' , _ , . . ! o _ Inch 1 1 / 4 1 / 4 7 / 16 2 3 / 16 - ( - _ - . . . . ! . . - . . . . . - . _ . - } _ - . £ lnm 32 6 11 56 l : s Standard 40 F3 - F5 I - O manual Rev4 l . doc Page 4 of 4
Page: 5

OIL BURNER COMPONENTS IDENTIFICATION STANDARD RIELLO OIL BURNER MODELS 40 F3 & 40 F5 BURNER KEY COMPONENTS 1 . 530 SE / C INTEGRATED PRIMARY CONTROL 7 . ELECTRONIC AIR SHUTTER ASSY . 2 . PRIMARY CONTROL SUB - BASE 8 . WIRE HARNESS FOR AIR SHUTTER 9 . COMBUSTION HEAD WITH DRAWER ASSY . 3 . FUEL UNIT ( PUMP ) 4 . PSC MOTOR 10 . SEMI FLANGE 2 PIECES 5 . CAPACITOR 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 . . . . . _ / ( 99 ) ( A ) 8511111 00025 . . . - - - I - - I Year ofmanuIhcture I BI - 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
Page: 6

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 . : t ® 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
Page: 7

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 . A 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
Page: 8

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 D ( COIL ) PUMP VALVE A - aK D I - - C SEE FIELD _ _ _ CAPA ( ITOR WIRING r - tl - - LEGEND : ( A ) BROWN ( B ) WHITE ( C ) BLUE ( 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
Page: 9

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 24V OPERATED SYSTEMS N d _ L _ SH _ ER L Q _ Q T O @ , D 120VAC 60HZ . 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
Page: 10

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
Page: 11

ELECTRODE SETTING IMPORTANT : THIS DIMENSIONS MUST 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 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 , Q 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
Page: 12

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 H 3 / 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 . NOTE : Do not exceed pipe lengths indicated in chart . Attach the required piping to this pipe adapter . Be sure that the plug in the RETURN PORT ( 7 ) is tightened securely . TWO LINE ( LIFT SYSTEM ) 2 LINE ( LIFT ) SYSTEM - PIPE LENGTHS H 3 / 8 " OD 1 / 2 " OD 1 FT M FT M FT M 0.0 0.0 ll5 35 330 100 P 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 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 two - Standard 40 F3 - F5 I - O manual Rev4 l . doc Page 12 of 12
Page: 13

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L _ W _ . _ A _ _ I _ N . _ G _ . ' . _ Tl ? _ . e , ' . Ph ' _ ei _ ni . eg _ h . t _ eL . e . 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 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 ) I . 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 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
Page: 14

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
Page: 15

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 NOZZLE PUMP RATE 5 % ± SIZE PRESSURE TURBULATOR AIR DAMPER US GPH GPH PSI BAR SETTING SETTING 0.50 . 40 x 60 ° / 80 ° 160 11.0 0.0 2.3 0.60 . 50 x 60 ° / 80 ° 150 10.4 0.5 2.7 0.75 . 60 x 60 ° / 80 ° 150 10.4 1.5 3.4 0.80 . 65 x 60 ° / 80 ° 150 10.4 2.0 3.6 0.95 . 75 x 60 ° / 80 ° 160 11.0 3.0 4.3 MODEL F5 BURNER SETUP CHART ACTUAL FIRING NOZZLE PUMP RATE 5 % ± SIZE PRESSURE TURBULATOR AIR DAMPER US GPH GPH PSI BAR SETTING SETTING 0.75 . 60 x 60 / 80 ° 145 10 0.0 2.25 0.85 . 65 x 60 / 80 ° 145 10 0.5 2.5 1.00 . 85 x 60 / 80 ° 145 l0 1.0 2.75 1.10 1.00 X 60 / 80 ° 145 10 2.0 3.0 1.25 1.10 x 60 / 80 ° 145 10 2.5 3.5 1.50 1.25 x 60 / 80 ° 145 10 3.0 4.25 1.65 1.35 X 60 / 80 ° 145 10 4.0 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
Page: 16

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 mounted position _ Head Receeded " If - t the flush - - _ 1 / 4 inch max . * " - _ 4 _ _ NO AMULET AMULET flue gases gases tapered combustion tapered combustion chamber causes chamber causes increase in pressure increase } n pressure inside inside LOW PRESSURE ] LOW PRESSURE I heat air tube air tube i H'GHPI RESSU E increase in heat pressure down air AMULET HELPS increase in pressure down air ncrease in pressure down air tube due to PREVENT HOT tube due to increase in tube due to increase in increase in GASES FROM combustion chamber combustion chamber combustion TRAVELLING pressure pressure chamber pressure DOWN AIR TUBE Standard 40 F3 - F5 I - O manual Rev4 l . doc Page 16 of 16
Page: 17

RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR © SHUTTER NORMAL OPERATIONAL SEQUENCE POWER I STANDY BY ELECTRIC AIR SHUTTER CLOSED ~ WAITING FOR CALL FOR HEAT n i _ m CALL FOR n i HEAT AIR open SHUTTER n i ELECTRIC AIR SHUTTER OPENS - ONCE FULLY OPEN SWITCHES POWER T + BURNER MOTOR [ _ 3 MOTOR / PREPURGE [ ( _ IGNITION I i Ol L VALVE [ ' FLAME [ © . _ HEAT _ q n SATISFIED I BURNER MOTOR STOPS ~ ELECTRIC AIR SHUTTER CLOSES _ AIR i SHUTTER ¢ S THERMOSTAT OR LIMIT CONTROL ELECTRIC AIR SHUTTER MODES © _ t3 u CONSTANT UNITERUPTED 120V POWER SUPPLY 40 SERIES OIL BURNER MODES TO ELECTRIC AIR SHUTTER ASSEMBLY J \ J
Page: 18

f mEl , l _ RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR SHUTTER NO FLAME OPERATIONAL SEQUENCE AC POWER I STANDY BY ELECTRIC AIR SHUTTER CLOSED - WAITING FOR CALL FOR HEAT CALL FOR HEAT AIR ELECTRIC AIR SHUTTER OPENS ~ ONCE FULLY OPEN SWITCHES POWER TO BURNER MOTOR SHUTTER open [ MOTOR / PREPURGE [ IGNITION [ OI L VALVE [ FLAME I LOCK OUT [ AIR I BURNER MOTOR STOPS - ELECTRIC AI } R SHUTTER CLOSES SHUTTER THERMOSTAT OR LIMIT CONTROL ELECTRIC AIR SHUTTER MODES CONSTANT UNITERUPTED 120V POWER SUPPLY 40 SERIES OIL BURNER MODES TO ELECTRIC AIR SHUTTER ASSEMBLY
Page: 19

& 4 : _ 11 10 W © 4 : _ I _ " o1 : © : = , / _ m ' ! 3 ! 49 ©
Page: 20

RIELLO SPARE PARTS LIST revised November 6 , 2002 • Indicates applicable model for each part . No CODE F3 F5 DESCRIPTION No CODE F3 F5 DESCRIPTION 1 3007232 Burner Back Cover 26 N / A Primary Control 2 3007233 Burner Back Cover 27 3005854 Semi Flange ( 2 Required ) 28 3005855 3006992 Pipe Connector Supply Universal Mounting Flange 3 29 3005856 3006571 3 / 8 " NPT / Metric Adapter - Male Mounting Gasket C7001081 4 3006993 Pipe Connector Return F3 replacement air damper kit 30 C7001082 5 3005847 t / 2 ' NPT / Metric Adapter - Female F5 replacement air damper kit 6 3007077 Crushable Metal Washer 3 / 8 " ID 7 3007568 Bleeder 8 3007028 O - Ring - Pump Pressure Regulator 9 3007202 Regulator Screw 3007207 Air Intake Housing 34 10 C7010002 O - Ring - Pump Cover ( 3007162 ) 3007208 Air Intake Housing 11 3005719 Pump Screen 35 3005844 Capacitor 12.5 ! JF 12 3006925 Valve Stem 36 3005708 Fan 13 3007203 Valve Stem Plate C6950050 Acoustic Liner 37 3007320 Acoustic Liner 14 3007029 O - Ring - Valve Stem Upper 3007221 Chassis Front Plate 15 3007156 O - Ring - Valve Stem Lower 38 3007222 Chassis Front Plate 16 3007268 Nozzle Outlet Fitting 17 3007087 Crushable Metal Washer 5 / 8 " ID 18 N / A Primary Control Sub - Base iiiiiii _ iiii _ i ` i _ i _ i ` i _ i _ _ i _ i ` ii ` _ i _ i _ i _ i ` ii ` _ i _ i _ i _ i ` ii ` _ i _ i _ i _ i ` ii ` _ i _ i _ i _ i ` ii ` _ i _ i ` ii _ _ ii ` _ i _ i ` ii _ _ ii ` _ i _ i ` ii _ _ ii ` _ i _ i ` ii _ _ ii ` _ i _ i ` ii _ _ ii ` _ i _ i _ i _ i ` ii ` _ i _ i _ i _ i ` ii ` _ i _ i _ i _ i ` ii ` _ i _ i _ i _ ` _ i ` ` ii _ _ 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 19 3006553 Coil U - Bracket and Knuded Nut 49 C7001033 Amulet - Cerafelt Sleeve Kit 20 3002279 Coil 50 C7001066 21 3007802 Pump Type L 24 volt switching relay 22 3000443 Pump Drive Key 23 3005843 Motor 120VOLT 60Hz 3007315 Air Tube Cover 24 3007316 Air Tube Cover 51 2623141 Capillary port plug 25 3002280 Photocell 52 3000932 Adjustable Steel Flange _ BT COMBU _ ION 3948876 VSBT Combustion Head 3 " 3948873 Short Combustion Head 6 " ( 271T1 ) 4O 4O 3948976 VSBT Combustion Head 3 " 3948973 Short Combustion Head 6 " ( 271T1 ) 3006968 Turbulator Disc 3006968 Turbulator Disc 41 41 3006977 Turbulator Disc 3006977 Turbulator Disc 42 3006966 42 3006966 Electrode Support Electrode Support 43 3006965 43 3006965 Nozzle Adapter Nozzle Adapter 3008627 Nozzle Oil Tube 3006969 Nozzle Oil Tube - Short 44 44 3008629 Nozzle Oil Tube 3006973 Nozzle Oil Tube - Short 3006324 3008633 Regulator Assembly Regulator Assembly - Short 45 45 3006323 3008634 Regulator Assembly Regulator Assembly - Short 3006330 3008630 Electrode Assembly Electrode Assembly - Short 46 46 3006329 3008631 Electrode Assembly Electrode Assembly - Short 47 3005869 Electrode Porcelain 47 3005869 Electrode Porcelain 3007592 3008623 Air Tube only Air Tube only 48 48 3007594 3008626 Air Tube only Air Tube only _ 7 / 8 " 3 _ B _ STION N _ 8 ; : ; ; : LOi | GC _ BEAD 40 3948877 Combustion Head 8 7 / 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 48 3008625 Air Tube only 3007595 Air Tube only Standard 40 F3 - F5 I - O manual Rev4 l . doc Page 20 of 20
Page: 21

mB , + + o 35 Pond Park Rd . 2165 Meadowpine Blvd . Hingham , MA 02043 Mississauga , On L5H R2 Phone : 781 - 749 - 8292 Phone : 905 - 542 - 0303 Toll Free : 800 - 992 - 7637 BURNERS Toll Free : 800 - 387 - 3898 Fax : 781 - 740 - 2069 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 : Burner Start - up Info ( GAS ) Gas Supply Pressure : Pump pressure : Turbulator Air Setting : setting : Air Setting : Head Setting : Draft Draft : ) raft Over fire : breech : Draft Over fire : breech : 002 : CO : 02 : 002 : CO : 02 : Manifold pressure : + Smoke density : ( Bacharach ) : Single [ _ 1 Tw ° [ _ l Ionization Reading Input : : i Line : I I Lines : I I ( 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
Page: 22

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 , 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
Page: 23

Standard 40 F3 - F5 I - O manual Rev4 l . doc Page 23 of 23
Page: 24

E [ L0 BURNERS 35 Pond Park Road 2165 Meadowpine Blvd Hingham , MA 02043 Mississauga , ON L5N 6H6 Phone 781 - 749 - 8292 Phone 905 - 542 - 0303 Toll Free 800 - 992 - 7637 Toll Free 800 - 387 - 3898 Fax 781 - 740 - 2069 Fax 905 - 542 - 1525 wx _ w . riellousa . com 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
"