Riello 40 F3 Installation instructions

Installation & Operating Manual
Single stage operation oil burners
MODEL TYPE
F3 WITH MANUAL AIR SHUTTER 261T
F5 WITH MANUAL AIR SHUTTER 262T
F3 WITH HYDRAULIC JACK (OPTION) 261T
F5 WITH HYDRAULIC JACK (OPTION) 262T
RETROFIT APPLICATIONS ONLY
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
C6501009 02/2012

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INSTALLATION PRECAUTIONS
AIR FOR COMBUSTION
Do not install burner 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 suffi-
cient 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 con-
nected 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 burner and explain its operation to the homeowner. Be sure to leave the Owner’s Instruction
sheet with the homeowner.
FIRE EXTINGUISHER
If required by local codes, install an approved fire 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.
The burner settings used in this manual were obtained under laboratory conditions and may vary
from those obtained in the actual installation of the burner. Combustion results must be verified
using proper combustion test equipment. Riello will not be responsible for the improper
installation or set-up of the appliance.
WARNING
ATTENTION

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TABLE OF CONTENTS
PACKAGE CONTENTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SERIAL NUMBER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Burner and mounting flange dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Burner components identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Burner components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
INITIAL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
ASSEMBLY OF AIR TUBE TO BURNER CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
MOUNTING BURNER TO BOILER OR FURNACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Method 1-Universal Mounting Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Method 2-Semi-flange Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Method 3-Pedestal Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
AMULET INSTALLATION INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
APPLICATION FIELD WIRING - RIELLO 530 SE/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
APPLICATION FIELD WIRING - RIELLO 530 SE/C 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
NOZZLE PLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
INSERTION / REMOVAL OF DRAWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
ELECTRODE SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TURBULATOR SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
OIL LINE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
PUMP PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SETTING THE AIR ADJUSTMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
BURNER ADJUSTMENT TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
BURNER START-UP CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
EXPLODED SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
BURNER START-UP FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

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PACKAGE CONTENTS LIST
Your Riello 40 burner should include the following parts. Please check to make sure all parts are present before begin-
ning the installation.
SERIAL NUMBER IDENTIFICATION
Your Riello burner may have been manufactured in more than one location and therefore there are two possible serial
number identification.
The Riello 9 character serial number, example,
06 01 12345, is identified as follows:
06 = Last two digits of the year of manufacture;
01 = Week of manufacture;
12345 = Increment of 1 for each burner produced – specific
to product code – reset to zero each January 1st.
The Riello 15 character serial number, example,
06 A 8511111 00025, is identified as follows:
06 = Last two digits of the year of manu-
facture;
A= BI-week of manufacture;
8511111 = Burner product code;
00025 = Increment of 1 for each burner pro-
duced – specific to product code –
reset to zero each January 1st.
Quantity Description
1 Burner chassis with cover
1 Universal mounting flange + mounting gasket
1 Parts bag
1 Parts bag
1 Installation manual
1Separate carton -OEM burners shipped with combustion head mounted
Combustion Head
Parts bag Parts bag
Quantity Description Quantity Description
1
1
1
1
1
1
By-pass plug
Female 1/4” NPT adapter
Male 3/8” NPT adapter
2.5 mm Allen key
Oil pump connector (supply)
Oil pump connector (return)
2
2
2
4
2
2
Semi-flange bolts (long)
Semi-flanges
Mounting flange bolts (short)
Nuts
Chrome nuts
Cover screws
(06) (01) (12345)
Year of
manufacture Week of manufacture Increment
(06) (A) (8511111) (00025)
Year of
manufacture Burner product code Increment
BI-week of
manufacture

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TECHNICAL DATA
SPECIFICATIONS
BURNER AND MOUNTING FLANGE DIMENSIONS
E1: 10-inch long (254mm) tubes are also available.
BURNER COMPONENTS IDENTIFICATION
Fuel No. 2 Fuel Oil
F3 Firing rate - Effective Output 0.50 to 0.95 US GPH - 70,000 to 133,000 BTU/h
F5 Firing rate - Effective Output 0.75 to 1.65 US GPH - 105,000 to 231,000 BTU/h
Voltage (single phase)
F3 Absorbed electrical power 175 Watts
F5 Absorbed electrical power 264 Watts
Motor (rated)
Capacitor 12.5 Microfarads
Pump pressure 130 to 200 psig
Primary control RIELLO 530 SE/C - RIELLO 530 SE/C 24V
Ignition transformer 8kV 16mA
Model A B C D E F
F3 Inches 8 15/32 9 59/64 6 15/32 3 1/2 6 8 29/32
mm 215 252 164 89 152 226
F5 Inches 9 11/64 10 11/16 7 3/32 3 1/2 6 9 13/32
mm 233 272 180 89 152 239
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°
BURNER COMPONENTS
1Lockout indicator lamp and reset button
2Primary control
3Primary control sub-base
4Pump pressure regulator
5Motor
6Air adjustment fixing screws
7Capacitor
8Combustion Head
9Semi Flange
10 Turbulator adjustment screw
11 Air tube cover
12 Coil
13 Vacuum gauge port
14 Pressure gauge and bleeder port
15 Return fuel line port
16 Supply fuel line port
17 Mounting flange with gasket
18 24V thermostat connections
(only 530 SE/C 24V)
D7351
D7352
B
A
EF
E1
CD
1
2
3
45
6
7
8
910 11
12
13
14
15
16
17
18
D8799
230v 50 Hz
2800 rpm Run Current 0.8 AMP

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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.
C) Remove drawer assembly from air tube, insert nozzle and set Turbulator adjustment for specific input required,
then set aside.
D) Mount air tube to burner chassis.
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, 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 AIR
TUBE HOLDING PATE (5) with the two holes on the BURNER 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.
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
S8015
S7461
A
B
A
B
DRY BASE
BOILER
D6013
D6014
COMBUSTION
CHAMBER

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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.
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 (9) 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 B
above). 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 insetting 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 (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 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.
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/fur-
nace 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 us-
ing 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, 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.
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 WILL DAMAGE THE END CONE.
WARNING

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AMULET INSTALLATION INSTRUCTIONS
(Required on some models)
The amulets provided have been selected by Riello to protect the
combustion tube from hot exhaust gases and flame. This protec-
tion may be needed in applications where the combustion tube
opening in the combustion chamber refractory is larger than the
tube outside diameter.
The amulet 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 amulet over the
combustion tube.
Excessive force can result in a broken amulet!
If the amulet 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 diagram below shows the proper position of the amulet after installation.
D7285
Amulet shown in the
flush mounted position
Head receeded
1/4 inch max.
NO AMULET AMULET
FLUE GASES FLUE GASES
Tapered combustion
chamber causes increase
in pressure inside
Tapered combustion
chamber causes increase
in pressure inside
HIGH PRESSURE HIGH PRESSURE
HEAT
HEAT
HEAT
HEAT
Increase in pressure down
air tube due to increase
in combustion chamber
pressure
Increase in pressure down
air tube due to increase
in combustion chamber
pressure
LOW PRESSURELOW PRESSURE
AIR TUBE AIR TUBE
Increase in pressure
down air tube due
to increase in
combustion chamber
pressure
Amulet helps prevent
not gases from
travelling down
air tube
S7941

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ELECTRICAL CONNECTIONS
It is advisable to leave the control box off the sub-base while com-
pleting the electrical connection to the burner.
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
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 a LOW VOLTAGE thermostat input (T-T).
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 - RIELLO 530 SE/C PRIMARY CONTROL
WARNING:
The hot (black) wire must be connected to the L terminal and the
neutral (white) wire must be connected to the N terminal or the
primary safety control will be damaged.
Do not connect wither wire to the terminal marked .
WARNING: DO NOT activate burner until proper oil line connections have been made, or failure of the pump
shaft seal may occur.
D7454
REMOTE SENSING OF
SAFETY LOCKOUT
The SAFETY SWITCH in
the 530 SE/C CONTROL
BOX is equipped with a con-
tact allowing remote sens-
ing of burner lockout. The
electrical connection is
made at terminal 4 (•) on
the SUB-BASE.
Should lockout occur the
530 SE/C CONTROL BOX
will supply a power source
of 120Vac to the connection
terminal.
The maximum allowable
current draw on this termi-
nal (4) is 1 Amp.
If a neutral or
ground lead is
attached to this
terminal, the
CONTROL BOX on the
burner will be damaged
should lockout occur.
WARNING
EARTH GROUND (Green)
NEUTRAL (White)
HOT LINE (Black)
EARTH GROUND (Green)
NEUTRAL (White)
HOT LINE (Black)
TRANSFORMER
Blue White Black Brown
White
Blue
Brown
Black
CAPACITOR
VALVE
MOTOR
COIL
234567891
NL
NLNL
FACTORY
WIRED
SUB-BASE
T
T24V
AC
120V
AC
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
120V
AC
Black
White
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
SWITCHING RELAY
M
~
D5995
DIRECT LINE LOW VOLTAGE
VOLTAGE

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APPLICATION FIELD WIRING - RIELLO 530 SE/C 24V PRIMARY CONTROL
REMOTE SENSING OF SAFETY LOCKOUT
The SAFETY SWITCH in the 530 SE/C 24V 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 530 SE/C 24V CONTROL BOX will supply a power source of 120Vac to the connection
terminal.
The maximum allowable current draw on this terminal (4) is 1 Amp.
If a neutral or ground lead is attached to this terminal, the CONTROL BOX on the burner will be
damaged should lockout occur.
T
T
J
T
T
123456789
AC
120 V
AC
120 V
D8794
FACTORY
WIRED
SUB-BASE
EARTH GROUND (GREEN) NEUTRAL (WHITE) HOT LINE (BLACK)
24V OPERATING
NL
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
NL NL
EARTH GROUND (GREEN) NEUTRAL (WHITE) HOT LINE (BLACK)
FUSE 15A
LINE SAFETY
SWITCH
SAFETY
LIMIT SWITCH LIMIT SWITCH
ON LEFT SIDE OF
THE CONTROL BOX
ON LEFT SIDE OF
THE CONTROL BOX
Blue
White
Black
Brown
White
Blue
Brown
Black
CAPACITOR
MOTOR
COIL
Black
White
DIRECT LINE LOW VOLTAGE
VOLTAGE
WARNING

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NOZZLE PLACEMENT
A) Determine the proper firing rate for the boiler or furnace units,
considering the specific application, and then use the Burner
Setup charts on page 11 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 AS-
SEMBLY 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 off oil delivery tube nut
from pump.
B) Loosen SCREW (3), and then un-
plug CONTROL BOX (1) by care-
fully pulling it back and then up.
C) Remove the AIR TUBE COVER
PLATE (5) by loosening the re-
taining SCREW (4) (Two
SCREWS – Model F5).
D) Loosen SCREW (2), and then
slide the complete drawer assem-
bly out of the combustion head as
shown.
E) To insert drawer assembly, re-
verse the procedure in items A to
D above.
ELECTRODE SETTING
IMPORTANT:
These dimensions must be observed and verified.
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: Zero and three are scale indicators only. From left to
right the first line is 3 and the last line 0.
MODEL F5: Same as above, except scale indicators are 0 and 4.
S7459
S8017
5/32” or 4 mm
5/32” to 13/64” or 4 to 5 mm
13/64”
5 mm
D6003
3
2
1
D7520

3222
9
GB
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.
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 (6) are supplied with the burner for connection to either a single or
two-line system. Also supplied are two ADAPTORS (3), two female 1/4” NPT, to adapt oil lines to burner pipe connec-
tors. All pump port threads are British Parallel Thread design. Direct connection of NPT threads to the pump will dam-
age the pump body.
Riello manometers and vacuum gauges do not require any adapters, and can be safely connected to the pump ports.
An NPT (metric) adapter must be used when connecting other gauge models.
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.
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.
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.
1
2
3
8
7
4
5
6
4
SINGLE LINE SYSTEM-PIPE LENGTHS
H 3/8” OD 1/2” OD
FT M FT M FT M
1.5 0.5 33 10 65 20
3.0 1.0 65 20 130 40
5.01.51304026080
6.52.019560325100
HP
D6009
ATTENTION:
do not exceed
pipe lengths
indicated in chart!

3222 10
GB
TWO LINE (LIFT SYSTEM)
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-mm 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-line system, supply and return 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 sys-
tem. Any obstructions in the return line will cause failure of the pump shaft seal.
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 startburner.
II. When bleeding the pump by pressure:
1) Loosen the bleeder valve (A).
2) Disconnect nozzle oil supply line at the pump nozzleport (B).
3) Attach a flexible plastic tube 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 re-
moved 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.
WARNING:
- Pipe dope or Teflon tapes are NOT to be used on any direct oil connection to the fuel pump.
- The height ‘P’ in Pipe Length Charts should not exceed 13 feet (4 m).
- The vacuum should not exceed 11.44 inches of mercury.
IMPORTANT:
An external, appropriately listed and certified oil filter must be placed in the fuel line between the fuel tank
and the burner pump.
To install the by-pass plug:
1) Remove the return plug (7).
2) Install the by-pass plug (4) using the 2.5 mm hexagonal key.
B) Attach the two PIPE CONNECTORS (6) to the pump SUPPLY and pump RETURN PORTS (5 and 7). Attach the re-
quired piping to these two pipe connectors using the NPT/ METRIC ADAPTERS that are supplied with the burner.
2 LINE (LIFT) SYSTEM-PIPE LENGTHS
H 3/8” OD 1/2” OD
FT M FT M FT M
0.00.011535330100
1.50.510030330100
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
D6008
HP
H
ATTENTION:
do not exceed
pipe lengths
indicated in chart!
D7284
C
A
B

3222
11
GB
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 of unburned oil in the combustion chamber creating a haz-
ardous situation upon burner startup.
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 suffi-
ciently purged, the hydraulic air shutter will open.
Once the burner is purged, turn off the power source and replace the air tube 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 any internal blockages.
WARNING! WHEN THE BYPASS PLUG IS INSTALLED, A TWO-PIPE SYSTEM MUST BE USED OR FAILURE OF
THE PUMP SHAFT WILL OCCUR.
SETTING THE AIR ADJUSTMENT PLATE
A) Regulation of the combustion airflow is made by adjustment of
the manual AIR ADJUSTMENT PLATE (4) after loosening the
FIXING SCREWS (3 & 5). The initial setting of the air adjust-
ment plate should be made according to BURNER ADJUST-
MENT TABLE.
B) The proper number on the manual AIR ADJUSTMENT PLATE
(4) should line up with the SETTING INDICATOR (2) on the fan
housing cover. Once set, the air adjustment plate should be se-
cured in place by tightening FIXING SCREWS (3 & 5).
C) The final position of the air adjustment plate will vary on each in-
stallation. Use instruments to establish the proper setting for
maximum CO2and a smoke reading of zero.
NOTE: Variations in flue gas, smoke, CO2and temperature read-
ings may be experienced when burner cover is put in place. There-
fore, the burner cover must be in place when making final
combustion instrument readings, to ensure proper test results.
The HYDRAULIC AIR SHUTTER (1) is operated by the HY-
DRAULIC JACK(6), assuring complete opening of the combus-
tion air intake.
Setting the air adjustment plate: same as above.
Manually open and release the HYDRAULIC AIR SHUTTER (1) to
ensure it has free movement.
4
5
3
1 6
2
D5555
4
5
3
2
D5820
OPTIONAL - pos. 1 - 6
OPTIONAL

3222 12
GB
BURNER ADJUSTMENT TABLE
NON-RETROFIT APPLICATIONS
If this burner is being installed in a packaged unit (i.e. Burner comes with a boiler or furnace), follow the instal-
lation and set-up instructions supplied with the heating appliance, as settings will differ from those shown in
this manual.
COMBUSTION CHAMBER
Follow the instructions furnished by the boiler/furnace manufacturer. Size retrofit application according to the appropri-
ate installation codes (e.g. CSA B139 or NFPA #31).
MODEL F3 BURNER
Actual firing
rate 5% ± Nozzle size Pump pressure Turbulator
setting Air damper setting
US GPH GPH PSI bar
0.50 .40 x 60º/80º 160 11.0 0.0 2.3
0.60 .50 x 60º/80º 150 10.4 0.5 2.7
0.75 .60 x 60º/80º 150 10.4 1.5 3.4
0.80 .65 x 60º/80º 150 10.4 2.0 3.6
0.95 .75 x 60º/80º 160 11.0 3.0 4.3
MODEL F5 BURNER
Actual firing
rate 5% ± Nozzle size Pump pressure Turbulator
setting Air damper setting
US GPH GPH PSI bar
0.75 .60 x 60/ 80º 145 10 0.0 2.25
0.85 .65 x 60/ 80º 145 10 0.5 2.5
1.00 .85 x 60/ 80º 145 10 1.0 2.75
1.10 1.00 X 60/ 80° 145 10 2.0 3.0
1.25 1.10 x 60/ 80º 145 10 2.5 3.5
1.50 1.25 x 60/ 80º 145 10 3.0 4.25
1.65 1.35 X 60/ 80° 145 10 4.0 6.0
The above set up charts are a starting point only.
The burner and appliance must be properly set up using proper combustion testing equipment.
Any approved oil burner nozzle type, angle and manufacturer maybe used, as long as input is cor-
responding the correct BTU/hr or US gph input rating of the appliance.
WARNING

3222
13
GB
BURNER START-UP CYCLE
Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp
~ 12s ~ 12s ~ 5s
D5229

GB
3222 14
EXPLODED SPARE PARTS LIST

GB
3222 15
SPARE PARTS LIST
No. CODE F3 F5 DESCRIPTION No. CODE F3 F5 DESCRIPTION
13020506 •BURNER BACK COVER
13020508 •BURNER BACK COVER
23006992 ••PIPE CONNECTOR - SUPPLY
33006571 ••3/8” NPT/METRIC ADAPTER - MALE
43006993 ••PIPE CONNECTOR - RETURN
53005847 ••1/4” NPT/ METRIC ADAPTER - FEMALE
63007077 ••CRUSHABLE METAL WASHER 3/8” ID
73007568 ••BLEEDER
83007028 ••O-RING - PUMP PRESSURE REGULATOR
93007202 ••REGULATOR SCREW
10 3007162 C7010002 ••O-RING - PUMP COVER
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 3001157 C7001029 ••PRIMARY CONTROL 530 SE/C
18 20010004 ••PRIMARY CONTROL 530 SE/C 24V
19 3002278 ••PRIMARY CONTROL SUB BASE
20 3006553 ••COIL U-BRACKET AND KNURLED NUT
21 3002279 ••COIL
22 3007802 C7001010 ••PUMP
23 3000443 ••PUMP DRIVE KEY
24
 3008451 ••
MOTOR
25 3007315 •AIR TUBE COVER
25 3007316 •AIR TUBE COVER
26 3002280 ••PHOTOCELL
27 3005854 ••SEMI FLANGE (2 REQUIRED)
28 3005855 ••UNIVERSAL MOUNTING FLANGE
29 3020248 C6880000 ••MOUNTING GASKET
30 3005708 ••FAN
31 3005798 ••
CAPACITOR 4 μF
32 3002864 C6950050 •ACOUSTIC LINER
32 3007320 •ACOUSTIC LINER
33 3007204 ••MANUAL AIR SHUTTER
OPTIONAL
60 3008048 C7001058 •CAPILLARY TUBE
60 3008049 C7001059 •CAPILLARY TUBE
61 3006911 ••HYDRAULIC JACK
62 3000878 ••HYDRAULIC AIR SHUTTER
63 C7001033 ••AMULET - CERAFELT SLEEVE KIT
64 C7001084 ••AL 1009 POST PURGE DEVICE KIT
65 3002761 ••DUCTED COMBUSTION AIR INTAKE KIT
C7001009 ••CAPILLARY PORT PLUG
3000932 ••ADJUSTABLE STEEL FLANGE

GB
3222 16
SPARE PARTS LIST
No. CODE F3 F5 DESCRIPTION No. CODE F3 F5 DESCRIPTION
40 3948876 •VSBT COMBUSTION HEAD 3”
40 3948976 •VSBT COMBUSTION HEAD 3”
41 3006968 •TURBULATOR DISC
41 3006977 •TURBULATOR DISC
42 3006966 ••ELECTRODE SUPPORT
43 3006965 ••NOZZLE ADAPTER
44 3008627 •NOZZLE OIL TUBE
44 3008629 •NOZZLE OIL TUBE
45 3008633 •REGULATOR ASSEMBLY
45 3008634 •REGULATOR ASSEMBLY
46 3008630 •ELECTRODE ASSEMBLY
46 3008631 •ELECTRODE ASSEMBLY
47 3005869 ••ELECTRODE PORCELAIN
48 3008623 •AIR TUBE
48 3008626 •AIR TUBE
40 3948873 •SBT COMBUSTION HEAD 6” (271T)
40 3948973 •SBT COMBUSTION HEAD 6” (271T)
41 3006968 •TURBULATOR DISC
41 3006977 •TURBULATOR DISC
42 3006966 ••ELECTRODE SUPPORT
43 3006965 ••NOZZLE ADAPTER
44 3006969 •NOZZLE OIL TUBE
44 3006973 •NOZZLE OIL TUBE
45 3006324 •REGULATOR ASSEMBLY
45 3006323 •REGULATOR ASSEMBLY
46 3006330 •ELECTRODE ASSEMBLY
46 3006329 •ELECTRODE ASSEMBLY
47 3005869 ••ELECTRODE PORCELAIN
48 3007592 •AIR TUBE
48 3007594 •AIR TUBE
40 3948877 •COMBUSTION HEAD 8 7/8”
40 3948975 •COMBUSTION HEAD 8 7/8”
41 3006968 •TURBULATOR DISC
41 3006977 •TURBULATOR DISC
42 3006966 ••ELECTRODE SUPPORT
43 3006965 ••NOZZLE ADAPTER
44 3008790 •NOZZLE OIL TUBE
44 3008628 •NOZZLE OIL TUBE
45 3008846 •REGULATOR ASSEMBLY
45 3008635 •REGULATOR ASSEMBLY
46 3008789 •ELECTRODE ASSEMBLY
46 3008632 •ELECTRODE ASSEMBLY
47 3005869 ••ELECTRODE PORCELAIN
48 3008788 •AIR TUBE
48 3008625 •AIR TUBE
40 3948874 •LBT COMBUSTION HEAD 10” (271T2)
40 3948974 •LBT COMBUSTION HEAD 10” (271T2)
41 3006968 •TURBULATOR DISC
41 3006977 •TURBULATOR DISC
42 3006966 ••ELECTRODE SUPPORT
43 3006965 ••NOZZLE ADAPTER
44 3006970 •NOZZLE OIL TUBE
44 3006974 •NOZZLE OIL TUBE
45 3005867 •REGULATOR ASSEMBLY
45 3005878 •REGULATOR ASSEMBLY
46 3005870 •ELECTRODE ASSEMBLY
46 3005880 •ELECTRODE ASSEMBLY
47 3005869 ••ELECTRODE PORCELAIN
48 3007593 •AIR TUBE
48 3007595 •AIR TUBE

3222
17
GB
BURNER START-UP REPORT
Model number: Serial number:
Project name: Start-up date:
Installing contractor: Phone number:
LIGHT OIL OPERATION
Oil supply pressure: CO2: Low Fire High Fire
Oil suction pressure: O2: Low Fire High Fire
Control Power Supply: CO: Low Fire High Fire
Burner Firing Rate: NOX: Low Fire High Fire
Low Fire Flame Signal: Net Stack Temp - Low Fire: High Fire
High Fire Flame Signal: Comb. Efficiency - Low Fire: High Fire
Low Fire Nozzle Size: Overfire Draft:
High Fire Nozzle Size: Smoke number:
CONTROL SETTINGS
Operating Setpoint: Low Oil Pressure:
High Limit Setpoint: High Oil Pressure:
Low Gas Pressure: Flame Safeguard Model
Number:
High Gas Pressure: Modulating Signal Type:
NOTES