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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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_
-(-_-.......!-......-_-}_-.£
l : s
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.
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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.
®
/
/
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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