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

2555
GB
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

2555
GB
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

2555
1
GB
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

2555
2
GB
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

2555
3
GB
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

2555
4
GB
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

2555
5
GB
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

2555
6
GB
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

2555
7
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.
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