Riello 40 F5 Installation instructions

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. Pleasecheck to make sure all parts are present before
beginningthe 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
]A
1
B
O
(< )"'Z
C
l
EIm II I_ ,
E1
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
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/__\ 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
]A
1
B
O
(< )"'Z
C
l
EIm II I_ ,
E1
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 1for 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.
®
: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

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
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-
D
I--
C
D
aK
CAPA(ITOR
r-tl-- SEE FIELD ___
WIRING
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

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
L
@,
D
120VAC 60HZ.
_Q
24V OPERATED SYSTEMS
Nd _ L _ SH_ER
120VAC 60HZ.
Q
T
O
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.
,Q 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)
1
P
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
ii
................................................................................................................................................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
ii
@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.
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 itsproper 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
150 10.4
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
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n i
n i
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[
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i
ELECTRIC AIR SHUTTER CLOSED ~WAITING FOR CALL FOR HEAT
ELECTRIC AIR SHUTTER OPENS -ONCE FULLY OPEN SWITCHES POWER T+ BURNER MOTOR
i
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
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open
POWER
STANDY BY
CALL FOR
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AIR
SHUTTER
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PREPURGE
IGNITION
OI L VALVE
FLAME
LOCK OUT
AIR
SHUTTER
RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR
SHUTTER NO FLAME OPERATIONAL SEQUENCE
I
ELECTRIC AIR SHUTTER CLOSED - WAITING FOR CALL FOR HEAT
ELECTRIC AIR SHUTTER OPENS ~ ONCE FULLY OPEN SWITCHES POWER TO BURNER MOTOR
[
[
[
[
I
[
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

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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)
Short Combustion Head 6" (271T1)
Turbulator Disc
Turbulator Disc
Electrode Support
Nozzle Adapter
Nozzle Oil Tube - Short
Nozzle Oil Tube - Short
Regulator Assembly - Short
Regulator Assembly - Short
Electrode Assembly - Short
Electrode Assembly- Short
Electrode Porcelain
Air Tube only
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
48 3008625 Air Tube only 3007595 Air Tube only
Standard 40 F3-F5 I-O manual Rev4 l.doc Page 20 of 20