Riello 40 F10 Installation instructions

2902554 (2) - 01/2009
Installation & Operating Manual
Single stage operation oil burner
CODE MODEL TYPE
3726313 F10 WITH MANUAL AIR SHUTTER 263T
NON-RETROFIT APPLICATIONS
If this burner is being installed in a packaged unit (ie. burner comes with a boiler or furnace), follow
the installation and set-up instructions supplied with the heating unit, as settings may differ from
those shown in this manual.
- The following pages contain information, descriptions and diagrams for the proper installation
and wiring of the burner. Please read carefully before attempting final installation.
- This manual is to remain with the final installation designation. It is the installer’s responsibility to en-
sure that the burner installation and operation instructions mentioned in this manual are followed and
operated within local code authority limits.
WARNING

F10 - I
PARTS LIST
Your Riello 40 F10 burner should include the following parts. Please check to make
sure all parts are present before beginning the installation.
*OEM burners shipped with combustion head mounted.
TABLE OF CONTENTS
TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OIL BURNER COMPONENTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . 2
F10 Burner Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Serial Number Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INITIAL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ASSEMBLY OF AIR TUBE TO BURNER CHASSIS. . . . . . . . . . . . . . . . . . . 3
MOUNTING THE BURNER TO BOILER OR FURNACE . . . . . . . . . . . . . . . 3
Method 1- Universal Mounting Flange . . . . . . . . . . . . . . . . . . . . . . . 3
Method 2- Semi-flange Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Method 3- Pedestal Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPLICATION FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
NOZZLE PLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSERTION/REMOVAL OF DRAWER ASSEMBLY . . . . . . . . . . . . . . . . . . . 7
ELECTRODE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TURBULATOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OIL LINE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Single Line (Gravity Feed System) . . . . . . . . . . . . . . . . . . . . . . . . . 9
Two Line (Lift System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PUMP PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Single Line (Gravity Feed System) . . . . . . . . . . . . . . . . . . . . . . . . . 11
Two Line (Lift System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SETTING THE AIR ADJUSTMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 12
BURNER SET-UP CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PRECAUTIONS - CANADA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PRECAUTIONS - U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPARE PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
QTY. DESCRIPTION (parts bag)
2 - Mounting flange bolts (short)
2 - Semi-flange bolts (long)
4 - Nuts
2 - Chrome nuts
1 - Oil pump connector (supply)
1 - Oil pump connector (return)
2 - Female 1/4” NPT adapter
1 - Male 3/8” NPT adapter
QTY. DESCRIPTION (carton)
1 - Burner chassis with cover
1 - Universal Mounting Flange
2 - Semi-flanges
1 - Mounting gasket
1 - Installation Manual
1 - By-pass plug
1 - 2.5 mm Allen key
* (separate carton)
1 - Combustion head

F10 - 1
RIELLO 40 F10
TECHNICAL DATA
DIMENSIONS
E1: 10 inch long (254 mm) tubes also available.
SPECIFICATIONS
FUEL: No. 2 Fuel Oil
FIRING RATE: 1.45 to 2.95 GPH 4.7 to 9.5 kg/h
EFFECTIVE OUTPUT: 203,000 to 413,000 BTU/h 59.5 to 121 kW
51,160 to 104,130 kcal/h
VOLTAGE (Single Phase): 120V 60 Hz (+10% –15%)
ABSORBED ELECTRICAL POWER: 230 Watts
MOTOR (rated): 3250 rpm Run Current 2.2 AMP
CAPACITOR: 12.5 Microfarads 260V
PUMP PRESSURE: 100 to 200 PSI
PRIMARY CONTROL: RIELLO 530 SE/C
IGNITION TRANSFORMER: 8kV 16 mA
MOUNTING FLANGE DIMENSIONS
MODEL F10 A B C D E F
Inches 10 5/16 12 8 1/32 3 15/16 5 10 7/16
mm 262 305 204 100 127 265
MODEL F10 A B C D
Inches 1 1/4 1/4 7/16 2 3/16
mm 32 6 11 56
D6012
BEF
A
C
D
E1
5 1/2”-140mm
7 1/2” - 190 mm
8 15/32” - 215 mm
7 3/32” - 180 mm
3 31/32”
101 mm
60°
45°
30°
B
C
A
D
D6000

F10 - 2
OIL BURNER COMPONENTS IDENTIFICATION
RIELLO 40 SERIES
F10 BURNER COMPONENTS
SERIAL NUMBER IDENTIFICATION
The Riello 15 character serial number, example, 97 A 8511111 00025, is identified as
follows: 97 = 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 - spe-
cific to product code - reset to zero each January 1st.
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 loosening the three screws securing it. Remove control
box and air tube cover (see page 7).
C) Remove drawer assembly from air tube, insert nozzle and set turbulator
adjustment for specific input required (see pages 7 & 8), then set aside.
D) Mount air tube to burner chassis (see page 3).
D6178
1
2
3
4
5
7
8
18
16 15 14
121110
17
9
136
1. Lockout indicator lamp and
Reset button
2. Primary control
3. Primary control sub-base
4. Pump pressure regulator
adjustment screw
5. Motor
6. Capacitor
7. Air adjustment fixing screws
8. Air shutter
9. End cone
10. Turbulator adjustment screw
11. Air tube cover
12. Coil
13. Vacuum gauge connection port
14. Pressure gauge and bleeder port
15. Return fuel line port
16. Supply fuel line port
17. Adjustable collar
18. Mounting flange with gasket
BI-week of manufacture burner product code
Year of Manufacture Sequence
(97) (A) (851111) (00025)

F10 - 3
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 their respective cartons.
B) Remove the DRAWER ASSEMBLY (1) from inside the AIR TUBE by loosening the
screw (2). Carefully pull the DRAWER ASSEMBLY out of the AIR TUBE, instal the
required nozzle (see page 7) and set aside.
C) Remove the two BOLTS (3) from FRONT PLATE (4) of the BURNER CHASSIS.
Align the two holes on the AIR TUBE HOLDING PLATE (5) with the two holes left open
on the BURNER CHASSIS FRONT PLATE when the BOLTS (3) were removed.
Replace the BOLTS and finger tighten only. Re-install DRAWER ASSEMBLY into AIR
TUBE. Tighten SCREW (2) securely (see page 7).
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 Boiler/Furnace unit.
2) Semi-flange collar bolted to Boiler/Furnace unit.
3) Universal flange mounted to optional Pedestal mount, where flange-mounting
direct to appliance is not possible. Pedestal kit must be ordered separately.
METHOD 1 - UNIVERSAL MOUNTING FLANGE
A) Insert the two BOLTS (1) into the UNIVERSAL MOUNTING 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.
S7462

F10 - 4
B) Position the MOUNTING GASKET (3) between the flat surface of the UNIVERSAL
MOUNTING FLANGE (10) and the appliance. Line up the holes in the UNIVERSAL
MOUNTING FLANGE with the STUDS (4) on the appliance mounting plate and
securely bolt the UNIVERSAL MOUNTING 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 is
properly positioned so the outside edge of
the END CONE will be at least 1/4 inch
(6.5 mm) back from the inside wall of the
refractory of the combustion chamber (see
dimension Bat right). The measured
length (A), is to include MOUNTING
GASKET and FLANGE, if used.
D) The burner may now be attached to the
heating unit by inserting the AIR TUBE
through the BURNER ACCESS HOLE (8)
and into the appliance, making sure the
BOLTS (1) line up with the two HOLES (5)
in the ADJUSTABLE COLLAR. 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 1/4” (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 hammer to form the holes.
S7461
A
B
A
B
COMBUSTION
CHAMBER
DRY
BASE
BOILER
D6013
D6014

F10 - 5
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
burner 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 1/4 inch
(6.5 mm) 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.
METHOD 3 - PEDESTAL MOUNT
Secure the MOUNTING FLANGE to MOUNTING PEDESTAL using the hardware
provided with the pedestal. Secure burner to MOUNTING FLANGE as in METHOD 1,
items 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.
ELECTRICAL CONNECTIONS
It is advisable to leave the control box off the sub-base while completing the electrical
connections to the burner.
WARNING: WHEN THE COMBUSTION CHAMBER IS LINED WITH A REFRAC-
TORY MATERIAL, IT IS IMPERATIVE THAT THE END CONE NOT PROTRUDE INTO
THE CHAMBER AREA, AS EXCESSIVE HEAT AT BURNER SHUT-DOWN WILL
DAMAGE THE END CONE.
1) Wire access hole
(Use BX electrical connector)
2) Earth ground conductor terminal
(GREEN WIRE)
3) Hot conductor terminal
(BLACK WIRE)
4) Neutral conductor terminal
(WHITE WIRE)
5) Strain relief clamp
WARNING: The hot (black) wire
must be connected to the Lter-
minal and the neutral (white)
wire must be connected to the N
terminal or the primary safety
control will be damaged.
Do not connect either wire to the
Terminal.
S7454

F10 - 6
The burner may be controlled using either a DIRECT LINE VOLTAGE control circuit
(120V AC 60 cycle) OR a LOW VOLTAGE control (24V AC 60 cycle) using a R8038A
Honeywell switching relay or equivalent.
Using the appropriate diagram below, make electrical connections to burner. All wiring
must be done in accordance with existing electrical codes, both national and local.
When all electrical connections have been made, the control box may be put back in
place on the sub-base.
APPLICATION FIELD WIRING
REMOTE SENSING OF SAFETY LOCKOUT: The SAFETY SWITCH in the 530SE
CONTROL BOX is equipped with a contact allowing remote sensing of burner lockout.
The electrical connection is made at terminal 4 () on the SUB-BASE. Should lockout
occur the 530SE CONTROL BOX will supply a power source of 120Vac to the con-
nection terminal. The maximum allowable current draw on this terminal (4) is 1 Amp.
WARNING: DO NOT activate burner until proper oil line connections have been
made, or failure of the pump shaft seal may occur.
WARNING: If a neutral or ground lead is attached to this terminal, the CONTROL
BOX on the burner will be damaged should lockout occur.
EARTH GROUND (GREEN)
NEUTRAL (WHITE)
HOT LINE (BLACK)
EARTH GROUND (GREEN)
NEUTRAL (WHITE)
HOT LINE (BLACK)
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
SWITCHING RELAY
BLUE
WHITE
BLACK
BROWN
WHITE
BLUE
BROWN
BLACK
CAPACITOR
VALVE
MOTOR
COIL
234567891
NL
NLNL
DIRECT LINE VOLTAGE LOW VOLTAGE
FACTORY
WIRED
SUB-BASE
T
T24V
AC
120V
AC
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
120V
AC
D5995
BLACK
WHITE

F10 - 7
NOZZLE PLACEMENT
A) Determine the proper firing rate
for the boiler or furnace unit, consid-
ering the specific application, then
use the Burner Set-up chart on page
12 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 overtighten).
D) Replace adapter, with nozzle installed, into drawer assembly and secure with
screw (1).
INSERTION/REMOVAL OF DRAWER ASSEMBLY
A) To remove drawer assembly, loosen SCREW (3), then unplug CONTROL BOX (1)
by carefully pulling it back and then up.
B) Remove the AIR TUBE COVER PLATE (5) by loosening the two retaining
SCREWS (4).
C) Loosen SCREW (2), then slide the complete drawer assembly out of the
combustion head as shown.
D) To insert drawer assembly, reverse the procedure in items A to C above, then
attach fuel line to the pump.
S7459
S7460

F10 - 8
ELECTRODE SETTING
TURBULATOR SETTING
A) Loosen NUT (1), then turn SCREW
(2) until the INDEX MARKER (3) is
aligned with the correct index number
as per the Burner Set-up chart, on
page 12.
B) Retighten the RETAINING NUT (1).
NOTE: Zero and five are scale indica-
tors only. From left to right, the first line
is 5 and the last line 0.
OIL LINE CONNECTIONS
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 shaft seal.
Note: Pump pressure must be set at time of burner start-up. A pressure gauge is
attached to the PRESSURE PORT (8) for pressure readings. Two PIPE
CONNECTORS (5) are supplied with the burner for connection to either a single or a
two-pipe system. Also supplied are two ADAPTORS (3), two female 1/4” NPT, to adapt
oil lines to burner pipe connectors. All pump port threads are British Parallel Thread
design. Direct connection of NPT threads to the pump will damage the pump body.
IMPORTANT:
THESE DIMENSIONS MUST BE OBSERVED AND VERIFIED.
5/32” or 4 mm
5/32” to 13/64” or 4 to 5 mm
13/64”
5 mm
D6003
3
2
1
D5997