Riello 40 Series Installation instructions

2902555 (4) - 11/2011
Installation & Operating Manual
Single stage operation oil burner
CODE MODEL TYPE
3726413 F15 WITH MANUAL AIR SHUTTER 264T
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

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INSTALLLATION 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.
WARNING

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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
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
APPLICATION FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
NOZZLE PLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSERTION / REMOVAL OF DRAWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRODE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TURBULATOR SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OIL LINE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PUMP PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SETTING THE AIR ADJUSTMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BURNER SET-UP CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DUCTED COMBUSTION AIR INTAKE APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BURNER START-UP CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EXPLODED SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BURNER START-UP REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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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 Code
1 Burner chassis with cover 3726413
1 Universal mounting flange + mounting gasket 2567395
1 Parts bag 2566282
1 Parts bag 2567338
1 Installation manual 2902555
1 By-pass plug
1Separate carton -OEM burners shipped with combustion head mounted
Air Tube/Drawer Assembly
Parts bag 2566282 Parts bag 2567338
Quantity Description Quantity Description
1
1
1
1
2
2
2
Female 1/4” NPT adapter
Male 3/8” NPT adapter
Oil pump connector (supply)
Oil pump connector (return)
Mounting flange bolts (short)
Nuts
Chrome nuts
2
2
2
2
Semi-flange bolts (long)
Semi-flange
Cover screws
Nuts
(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
Firing rate 2.55 to 5.75 GPH 8.2 to 18.6 kg/h
Effective output 357,000 to 805,000 BTU/h - 104.6 to 235.8 kW
89,960 to 202,860 kcal/h
Voltage (single phase) 120V 60Hz (+ 10% - 15%)
Absorbed electrical power 450 Watts
Motor (rated) 3250 rpm Run Current 4 AMP
Capacitor 16 Microfarads 260V
Pump pressure 100 to 200 psi
Primary control RIELLO 530 SE/C 24V
Ignition transformer 8kV 16mA
Model F15 A B C D E F G H I L
Inches 11 3/4 13 25/32 9 1/16 4 11/16 5 11 27/32 1 1/2 1/4 7/16 2 7/8
mm 298 350 230 119 127 301 38 6 11 73
D8860
B
A
EF
E1
C
D
1
2
3
4
5
7
8
6
18
16 15 14
13
12
19
11
10
17
9
20
BURNER COMPONENTS
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
9Endcone
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
19 24V thermostat connections
20 Solenoid valve
6 17/32”-166mm
8 1/4” - 210 mm
9 1/4” - 235 mm
7 7/8” - 200 mm
4 31/32”
126 mm
60°
45°
30°
H
I
G
L
D6000
D12173

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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 burn-
er 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.
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
S7452
S7439
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 ap-
pliance 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 appli-
ance 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/
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, 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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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 VOLT-
AGE control circuit (120V AC 60 cycle) OR:
- a LOW VOLTAGE thermal input (T-T) if the primary control 530SE/C 24V is used;
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.
NOTE: Terminal 4 is to be used to activate a remote safety lockout circuit only. A 120V AC source is supplied to Terminal
4 upon lockout. The maximum allowable current draw for this circuit is 1 AMP.
IMPORTANT: if a neutral or ground lead is attached to Terminal 4, the control box will be damaged should lockout occur.
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
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
234567891
NL
NLNL
DIRECT LINE LOW VOLTAGE
FACTORY
WIRED
SUB-BASE
T
T
24V
AC
120V
AC
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
White
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
SWITCHING RELAY
M
~
D7513
120V
AC
VALVE
SAFETY
VOLTAGE

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NOZZLE PLACEMENT
A) Determine the proper firing rate for the boiler or furnace
unit, considering the specific application, then use the
Burner Set-up chart 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 as-
sembly and secure with screw (1).
INSTALLATION/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.
ELECTRODE SETTING
IMPORTANT:
These dimensions must be observed and verified.
TURBULATOR SETTING
A) Loosen NUT (1), then turn SCREW (2) until the INDEX MARK-
ER (3) is aligned with the correct index number as per the Burn-
er Set-up chart.
B) Retighten the RETAINING NUT (1).
NOTE:
Zero and five are scale indicators only.
From left to right, the first line is 5 and the last line 0.
S7437
S7453
5/32” or 4 mm
5/32” to 13/64” or 4 to 5 mm
13/64”
5 mm
D6003
3
2
1
D5997

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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.
Riello manometers and vacuum gauges do not require any adaptors, and can be safely connected to the pump
ports. An NPT (metric) adapter must be used when connecting other gauge models.
6
54
8
2
3
1
4
D6183
9

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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 cov-
er (1) before re-attaching the pump cover to the pump
housing.
B) Connect the pipe connector to the SUPPLY PORT
(6) of the pump. Attach the required piping to this
pipe connector. Be sure that the plug in the
RETURN PORT (9) is tightened securely.
TWO LINE (LIFT SYSTEM)
A) If a two line system is required, install the By-pass
plug (4) provided. The by-pass plug is installed in
the return port (9) 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 system.
Any obstructions in the return line will cause failure
of the pump shaft seal. Do not exceed the pipe
lengths indicated in the tables.
To install the by-pass plug:
1) Remove the return plug (9).
2) Install the by-pass plug (4) using the 2.5 mm
hexagonal key.
B) Attach the two PIPE CONNECTORS (5) to the
pump SUPPLY and pump RETURN PORTS (6 and
9). Attach the required piping to these two pipe
connectors using the NPT/METRIC ADAPTERS
that are supplied with the burner.
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.
SINGLE LINE SYSTEM - PIPE LENGTHS
H 3/8”OD 1/2”OD
Feet Meters Feet Meters Feet Meters
1 1/2 0.5 33 10 65 20
3 1.0 65 20 130 40
5 1.5 130 40 260 80
6 1/2 2.0 195 60 325 100
HP
D6009
ATTENTION:
do not exceed
pipe lengths
indicated in chart!
2 LINE (LIFT) SYSTEM - PIPE LENGTHS
H3/8”OD1/2”OD
Feet Meters Feet Meters Feet Meters
0 0.0 115 35 330 100
1 1/2 0.5 100 30 330 100
3 1.0 80 25 330 100
5 1.5 65 20 295 90
6 1/2 2.0 50 15 230 70
9 1/2 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!

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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)
A) Loosen the bleeder valve (A) until oil flows out. Tighten the
bleeder valve securely and start burner.
B) 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 tube to the pump nozzle port, directing
the oil flow into a bucket.
4) Loosen the screws securing the air tube cover, allowing it to
be removed freely.
5) Holding the air tube cover in its proper location start the
burner.
6) When the solenoid valve is engaged, approximately 10 seconds after starting, remove the air tube cover and shine a
light source on the photo-cell, 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 of unburned oil in the combustion chamber creating a hazardous sit-
uation upon burner startup.
B) TWO LINE (LIFT SYSTEM)
Turn off the main power source to the burner and remove the air tube cover.
Shine a light source on the photo-cell (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.
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 SEAL WILL OCCUR.
D6185
A
C
B

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SETTING THE AIR ADJUSTMENT PLATE
A) Regulation of the combustion air flow is made by adjustment
of the manual AIR ADJUSTMENT PLATE (1) after
loosening the FIXING SCREWS (2 & 3). The initial setting of
the air adjustment plate should be made according to
Column 5 in the Burner Set-up Chart.
B) The proper number on the manual AIR ADJUSTMENT PLATE
(1) should line up with the SETTING INDICATOR (4) on the
fan housing cover. Once set, the air adjustment plate should
be secured in place by tightening SCREWS 2 and 3.
C) The final position of the air adjustment plate will vary on each
installation. Use instruments to establish the proper settings
for maximum CO2and a smoke reading of zero.
NOTE:
Variations in flue gas, smoke, CO2and temperature readings
may be experienced when the burner cover is put in place.
Therefore, the burner cover must be in place when making the
final combustion instrument readings, to ensure proper test
results.
BURNER SET-UP CHART
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 will differ from those shown
in this manual.
NOZZLES RECCOMANDED:
Monarch R-PLP, Delavan W-B, Danfoss S-B, Steinen SS-S, Hago P.
NOTE:
A 45° degree nozzle is suggested, however, a 60° degree nozzle may be used in cases where the flame is
unstable at light-off when operated at low ambient temperatures.
1 2 3 4 5
Actual Firing
Rate ± 5%
Nozzle
Size
Pump
Pressure Turbulator
Setting
Air Damper
Setting
GPH kg/h GPH PSI bar
2.55 8.2 2.00 x 45°/60° 170 11.6 0.0 1.8
2.85 9.2 2.25 x 45°/60° 160 11 0.5 2.0
3.00 9.7 2.50 x 45°/60° 150 10 1.0 2.2
3.65 11.8 3.00 x 45°/60° 150 10 1.5 2.6
4.25 13.7 3.50 x 45°/60° 150 10 2.0 3.1
4.85 15.7 4.00 x 45° 150 10 3.0 4.5
5.45 17.6 4.50 x 45° 150 10 4.5 5.2
5.75 18.6 5.00 x 45° 140 9.6 5.0 5.5
D5231
2
1
34

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DUCTED COMBUSTION AIR INTAKE APPLICATIONS
The “Ducted combustion air intake kit” (see P.N. 3002762 in the spare parts list - OPTIONAL), allows ducting of exter-
nal air directly into the burner. A 4” diameter air intake is provided in the kit.
The settings of the burner must be according to the BURNER SETUP CHART – AIR INTAKE APPLICATIONS below.
NOZZLES RECCOMANDED:
Monarch R-PLP, Delavan W-B, Danfoss S-B, Steinen SS-S, Hago P.
NOTE:
A 45° degree nozzle is suggested, however, a 60° degree nozzle may be used in cases where the flame is
unstable at light-off when operated at low ambient temperatures.
NOTES:
A) This kit is not suitable for direct vent applications.
B) Always try to minimize the length of the air intake pipe.
C) Reduce pipe length by 10 feet for every 90° elbow, 5 feet for every 45° elbow.
D) Reduce pipe length by 6 feet for the 4” to 6” pipe adapter (if used).
E) Air intake venting should be insulated 10 feet from air intake source with a minimum R7 foil lined insulation, to prevent
condensation or corrosion of air intake venting.
F) Use an approved type of air intake vacuum breaker and install it in the same room of the burner.
This device should be tested to prove that the vacuum breaker balancer is set correctly and, in the event of intake air
source being blocked, can provide enough combustion air for the burner. If the room where the burner is installed
cannot provide enough air or air quality is a concern, an additional air inlet source must be provided to this room.
G) On the outside of the wall, use an approved intake air hood, located above the snow line and in such way as to prevent
leaves and/or other debris from blocking the air flow. Refer to local codes for proper location of inlet.
To mount this kit on the burner, please follow the installation description given in the kit instruction sheet.
Use a 4” to 6” pipe adapter (not supplied in the kit) to use a 6” diameter pipe.
MODEL F15 BURNER SETUP CHART with 4" diameter pipe
Actual
firing rate
GPH
Nozzle
size
Pump
pressure
PSI
Head
setting
20 Ft.
pipe length
50 Ft.
pipe length
80 Ft.
pipe length
100 Ft.
pipe length
Air Setting Air Setting Air Setting Air Setting
2.55 2.00 x 45°/60° 160 0.0 2.0 2.1 2.1 2.1
2.85 2.25 x 45°/60° 160 1.0 2.3 2.4 2.4 2.5
3.10 2.50 x 45°/60° 150 2.0 2.3 2.4 2.4 2.5
3.65 3.00 x 45°/60° 150 3.0 2.9 3.3 3.4 3.5
4.30 3.50 x 45°/60° 150 4.0 3.5 4.1 4.1 4.4
5.14 4.00 x 45°/60° 165 5.0 6.0 6.0 6.1 6.4
MODEL F15 BURNER SETUP CHART with 6" diameter pipe
Actual
firing rate
GPH
Nozzle
size
Pump
pressure
PSI
Head
setting
20 Ft.
pipe length
50 Ft.
pipe length
80 Ft.
pipe length
100 Ft.
pipe length
Air Setting Air Setting Air Setting Air Setting
2.55 2.00 x 45°/60° 160 0.0 2.0 2.0 2.1 2.2
2.85 2.25 x 45°/60° 160 1.0 2.3 2.3 2.4 2.4
3.10 2.50 x 45°/60° 150 2.0 2.3 2.3 2.4 2.4
3.65 3.00 x 45°/60° 150 3.0 2.9 3.0 3.0 3.1
4.30 3.50 x 45°/60° 150 4.0 3.5 4.1 4.1 4.2
5.14 4.00 x 45°/60° 165 4.5 5.5 5.6 5.6 5.7
5.60 4.50 x 45°/60° 155 5.0 6.1 6.2 6.3 6.4

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COMBUSTION CHAMBER
Follow the instructions furnished by the boiler/furnace manufacturer. Size retrofit application according to the appropriate
installation codes (eg. CSA B139 or NFPA #31).
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
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EXPLODED SPARE PARTS LIST

GB
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SPARE PARTS LIST
No. CODE DESCRIPTION No. CODE DESCRIPTION
1 3020510 BURNER BACK COVER
2 3006571 3/8” NPT/METRIC ADAPTER - MALE
3 3006994 PIPE CONNECTOR - SUPPLY AND RETURN
4 3005847 1/4” NPT/ METRIC ADAPTER - FEMALE
5 3007077 CRUSHABLE METAL WASHER
6 3007568 BLEEDER
7 3007028 O-RING - PUMP PRESSURE REGULATOR
8 3007202 REGULATOR SCREW
9 3007162 C7010002 O-RING - PUMP COVER
10 3005719 PUMP SCREEN
11 3006925 VALVE STEM
12 3007203 VALVE STEM PLATE
13 3007029 O-RING - VALVE STEM UPPER
14 3007156 O-RING - VALVE STEM LOWER
15 3002278 PRIMARY CONTROL SUB BASE
16 3007268 NOZZLE OUTLET FITTING
17 3007087 CRUSHABLE METAL WASHER
18 3006553 COIL U-BRACKET AND KNURLED NUT
19 3002279 COIL
20 3007802 C7001010 PUMP
21 3000443 PUMP DRIVE KEY
22 3005845 MOTOR
23 3007318 AIR TUBE COVER
24 3002280 PHOTO-CELL
25 20010004 PRIMARY CONTROL 530SE/C 24V
26 3005849 SEMI FLANGE
27 3005852 MOUNTING GASKET
28 3005851 UNIVERSAL MOUNTING FLANGE
29 3007206 MANUAL AIR SHUTTER
30 3007211 AIR INTAKE HOUSING
31 3005799 FAN
32 3007358 ACOUSTIC LINER
33 3005846 CAPACITOR 16 µF
50 3020300 OIL LINE
51 3020307 MALE ADAPTOR
52 3020299 SOLENOID VALVE
53 3020304 ADAPTOR
54 3020301 OIL LINE
55 3020303 ADAPTOR AND NUT
56 3020302 BRACKET
40 3949171 SHORT COMBUSTION HEAD 5” (274T1)
41 3005892 SHORT AIR TUBE
42 3005897 TURBULATOR DISC
43 3005896 CROSS - CASTING
44 3006965 NOZZLE ADAPTER
45 3006987 NOZZLE OIL TUBE - SHORT
46 3005900 REGULATOR ASSEMBLY - SHORT
47 3005902 ELECTRODE ASSEMBLY - SHORT
48 3005869 ELECTRODE PORCELAIN
49 3005895 END CONE
40 3949172 LONG COMBUSTION HEAD 10” (274T2)
41 3005893 LONG AIR TUBE
42 3005897 TURBULATOR DISC
43 3005896 CROSS - CASTING
44 3006965 NOZZLE ADAPTER
45 3006988 NOZZLE OIL TUBE - LONG
46 3005901 REGULATOR ASSEMBLY - LONG
47 3005903 ELECTRODE ASSEMBLY - LONG
48 3005869 ELECTRODE PORCELAIN
49 3005895 END CONE
OPTIONAL
60 3007816 CAPILLARY TUBE
61 3006911 HYDRAULIC JACK
62 3000880 HYDRAULIC AIR SHUTTER
63 3002762 DUCTED COMBUSTION AIR INTAKE KIT

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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

Subject to modifications
RIELLO BURNERS NORTH AMERICA
35 Pond Park Road 1-800-4-RIELLO 2165 Meadowpine Blvd
Hingham, Massachusetts, 1-800-474-3556 Mississauga, Ontario
U.S.A. 02043 Canada L5N 6H6
http://www.riello-burners.com
RIELLO S.p.A.
I-37045 Legnago (VR)
Tel.: [phone]
http:// www.riello.it
http:// www.rielloburners.com