Riello 40BF Installation instructions

Installation & Operating Manual
C6505027 - 20015900 (3) - 07/2014
Single stage operation oil burners
CODE MODEL TYPE
3729010 BF3 290T
3729110 BF5 291T
RETROFIT APPLICATIONS ONLY
If this burner is being installed in a packaged unit (ie. burner comes with a boiler or furnace), follow
the installation and set-up instructions supplied with the heating unit, as settings may differ from
those shown in this manual.
- The following pages contain information, descriptions and diagrams for the proper installation
and wiring of the burner. Please read carefully before attempting final installation.
- This manual is to remain with the final installation designation. It is the installer’s responsibility to en-
sure that the burner installation and operation instructions mentioned in this manual are followed and
operated within local code authority limits.
This burner is not equipped for 2 line operation.
For 2 line operation order: part # C7001025 for BF3, C7001026 for BF5.
WARNING
BF

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INSTALLATION PRECAUTIONS
AIR FOR COMBUSTION
Do not install burner in room with insufficient air for combustion. Be sure there is an adequate air supply for
combustion if the boiler room is enclosed. It may be necessary to create a window to permit sufficient air to
enter the boiler room. The installer must follow local ordinances in this regard.
CANADA It is suggested that the installer follow CSA standard B139.
USA It is suggested that the installer follow NFPA manual #31.
CHIMNEY
Be sure chimney is sufficient to handle the exhaust gases. It is recommended that only the burner be con-
nected to the chimney. Be sure that it is clean and clear of obstructions.
OIL FILTER
An external oil filter is REQUIRED, even though there is an internal strainer in the pump. The filter should be
replaced at least once a year, and the filter container should be thoroughly cleaned prior to installing a new
filter cartridge.
DRAFT
Follow the instructions furnished with the heating appliance. The pressure in the combustion area should be
kept as close to zero as possible. The burner will operate with a slight draft or pressure in the chamber.
ELECTRICAL CONNECTIONS
CANADA All electrical connections should be done in accordance with the C.E.C. Part 1, and all local codes.
The system should be grounded.
USA All electrical connections should be done in accordance with the National Electrical Code, and all
local ordinances. The system should be grounded.
CONTROL BURNER OPERATION
Check out the burner and explain its operation to the homeowner. Be sure to leave the Owner’s Instruction
sheet with the homeowner.
FIRE EXTINGUISHER
If required by local codes, install an approved fire extinguisher.
ELECTRICAL CONNECTIONS
In most localities, a number 14 wire should be used inside a metal conduit. The system should be grounded.
A service switch should be placed close to the burner on a fireproof wall in an easily accessible location.
The burner settings used in this manual were obtained under laboratory conditions and may vary
from those obtained in the actual installation of the burner. Combustion results must be verified
using proper combustion test equipment. Riello will not be responsible for the improper
installation or set-up of the appliance.
ATTENTION
ATTENTION

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TABLE OF CONTENTS
PACKAGE CONTENTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SERIAL NUMBER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Burner and mounting flange dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Burner components identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MOUNTING THE BURNER TO BOILER OR FURNACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
APPLICATION FIELD WIRING - RIELLO 530 SE/C PRIMARY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
APPLICATION FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
APPLICATION FIELD WIRING - RIELLO 530 SE/C 24 VPRIMARY CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
INSTALLATION/ REMOVAL OF DRAWER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ELECTRODE SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
NOZZLE PLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TURBULATOR SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
OIL LINE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PUMP PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
SETTING THE AIR ADJUSTMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
COMBUSTION CHAMBER PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
BURNER START-UP CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
BURNER ADJUSTMENT TABLES - BURNER SETUP CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A TYPICAL LAYOUT FOR BF BURNER INTAKE AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
TROUBLE SHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
EXPLODED SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
BURNER START-UP LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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PACKAGE CONTENTS LIST
Your Riello 40 BF burner should include the following parts. Please check to make sure all parts are present before be-
ginning the installation.
SERIAL NUMBER IDENTIFICATION
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 3729010 - 3729110
1 Gasket 2567340
1 Nut 2621854
1 Connector 2623842
1 Installation manual
(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
BURNER COMPONENTS IDENTIFICATION
Fuel No. 2 Fuel Oil
BF3 Firing rate - Effective Output 0.50 to 0.95 US GPH - 70,000 to 133,000 BTU/h
BF5 Firing rate - Effective Output 0.75 to 1.65 US GPH - 105,000 to 231,000 BTU/h
Voltage (single phase) 120V 60Hz (+ 10% - 15%)
BF3 Absorbed electrical power 192 Watts
BF5 Absorbed electrical power 204 Watts
Motor (rated) 3250 rpm Run Current 2.2 AMP
Capacitor 12.5 Microfarads 260V
Pump pressure 100 to 200 PSI
Primary control RIELLO 530 SE/C - RIELLO 530 SE/C 24 V
Ignition transformer 8kV 16mA
Model ABCDE*E1F
BF3 Inches 9 13/16 11 1/4 7 1/2 3 1/2 4 1/4 6 8 1/4
mm 249 286 193 89 108 152 210
BF5 Inches 9 13/16 11 1/2 7 1/2 3 1/2 4 1/4 8 7/8 8 3/4
mm 249 292 193 89 108 225 222
5 9/16”-141mm
7 9/16” - 192 mm
8 1/2” - 216 mm
3 9/16”
90 mm
60°
45°
30°
BURN-
ER COMPONENTS
1Lockout indicator lamp and reset button
2Primary control
3Primary control sub-base
4Pump pressure regulator
5Post purge timer (option)
6Air adjustment
7Capacitor
8Combustion head
9Mounting gasket
10 Universal mounting flange
11 Turbolator adjustment screw
12 Coil
13 Bleeder and pressure gauge port
14 Return fuel line port
15 Inlet fuel line port
16 Pump
17 24 V thermostat connections
D7516
D7515
B
A
EF
C
D
*E1
03
D7517
1
2
3
45
6
7
15
8 9 10
12
1314
16
11
17
*E1: 6” (152 mm) 8 7/8” (225mm) & 10” (254 mm) tubes are also available.

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MOUNTING THE BURNER TO THE BOILER OR FURNACE
There are two possible methods to mount the burner, depending on the individual application. These are:
1) Universal flange bolted to Boiler/Furnace unit.
2) 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
A) Slide the UNIVERSAL MOUNTING FLANGE (1) over
the end cone assembly with the flat flange surface to-
wards the heating unit.
B) Secure the UNIVERSAL MOUNTING FLANGE to the
AIR TUBE by tightening the ALLEN BOLT (2). Be sure
that the MOUNTING FLANGE is properly positioned. The
outer edge of the END CONE will be at least 1/4” (6.5
mm) back from the inside wall of the refractory chamber
or inside wall of the combustion chamber (see dimension
B above). The measured length (A) is to include the
MOUNTING GASKET (3) and FLANGE.
C) For dry based appliances it is suggested that an amu-
let or cera-felt sleeve be used on the end cone to help re-
duce the risk of end cone burn-off. This amulet also
provides an additional benefit of sealing the chamber air
tube hole when this hole is larger then our air tube diam-
eter. Please refer to amulet instructions in regards to in-
stalling amulet to the burners air tube end cone.
D) The burner can now be attached to the heating unit by
inserting the AIR TUBE through the BURNER ACCESS
HOLE (5) and into the appliance, making sure the
MOUNTING FLANGE lines up with the appliance studs
(6). Secure the burner in place using nuts (4).
A visual verification of the air tube insertion into the com-
bustion chamber of the heating unit is suggested. Dimen-
sion “B” should be at least 1/4 inch (see drawing).
METHOD 2 – PEDESTAL MOUNT
Secure the MOUNTING FLANGE to MOUNTING PED-
ESTAL using the hardware provided with the pedestal.
Secure burner to MOUNTING FLANGE as in METHOD
1.
NOTE: It is suggested that the pedestal be anchored in
position on the floor by installing brackets over the ped-
estal tube and securing brackets to the floor.
WHEN THE COMBUSTION CHAM-
BER IS LINED WITH A REFRACTORY
MATERIAL, IT IS IMPERATIVE THAT
THE END CONE NOT PROTRUDE
INTO THE CHAMBER AREA, AS EXCESSIVE
HEAT AT BURNER END CONE DURING OPER-
ATION OR SHUTDOWN WILL DAMAGE THE
END CONE. IF HIGH END CONE TEMPERA-
TURES ARE A CONCERN USING A CERA-FELT
SLEEVE OR, AMULET OVER THE END CONE
COULD HELP REDUCE THE RISK OF BURN-
OFF THE END CONE.
D9646
42
125
6
CERA-FELT
SLEEVE OR
AMULET
SHOWN
D9647
D9648
WET BASED
CHAMBER
APPLICATIONS
DRY BASED
CHAMBER
APPLICATIONS
WARNING

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ELECTRICAL CONNECTIONS
It is advisable to leave the control box off the sub-base while
completing the electrical connections to the burner.
1) Electrical connector
2) Earth ground conductor terminal
The burner may be controlled using either a DIRECT LINE
VOLTAGE control circuit (120V AC 60 cycle) OR a LOW
VOLTAGE control (24V AC 60 cycle) using models Riello or
Honeywell R8038A 24v relays or a LOW VOLTAGE
THERMOSTAT INPUT (T-T).
Following the wiring diagram on the next page, make electrical
connections to burner. All wiring must be done in accordance
with existing electrical codes, both National and Local.
Do not activate burner until proper oil line connections have been made, or failure of the pump shaft seal may
occur.
APPLICATION FIELD WIRING - RIELLO 530 SE/C PRIMARY CONTROL
S7954
WARNING
REMOTE SENSING OF
SAFETY LOCKOUT
The SAFETY SWITCH in
the 530 SE/C CONTROL
BOX is equipped with a con-
tact allowing remote sens-
ing of burner lockout. The
electrical connection is
made at terminal 4 (•) on
the SUB-BASE.
Should lockout occur the
530 SE/C CONTROL BOX
will supply a power source
of 120Vac to the connection
terminal.
The maximum allowable
current draw on this termi-
nal (4) is 1 Amp.
If a neutral or
ground lead is
attached to this
terminal, the
CONTROL BOX on the
burner will be damaged
should lockout occur.
WARNING
EARTH GROUND (Green)
NEUTRAL (White)
HOT LINE (Black)
EARTH GROUND (Green)
NEUTRAL (White)
HOT LINE (Black)
TRANSFORMER
Blue White Black Brown
White
Blue
Brown
Black
CAPACITOR
VALVE
MOTOR
COIL
234567891
NL
NLNL
FACTORY
WIRED
SUB-BASE
T
T24V
AC
120V
AC
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
120V
AC
Black
White
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
SWITCHING RELAY
M
~
D5995
DIRECT LINE LOW VOLTAGE
VOLTAGE

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APPLICATION FIELD WIRING
Capacitor
GREEN
BLUE
BLACK
BLACK
WHITE
BLUE
M
BROWN
AL 1009-1
Burner Fan-Off
Timer
6
12
8
N
1
11
9
3
27
YELLOW
BLUE
BLUE
RED
GREY
L
WHITE
BLACK
RED
WGR B
WHITE RED
BROWN
Ground
FACTORY WIRED
SUB BASE
LIMIT
Switches
SAFETY
Switches
Fuse 15A
L1L2 Earth
Ground
WHITE GREEN RED BLACK
Motor
FIELD
WIRING
Oil Valve Control Box
530 SE/C
4
All the installation, maintenance and disassembly operations MUST be carried out with the electric-
ity supply disconnected.
The installation of the burner must be carried out by qualified personnel, as indicated in this manual
and in compliance with the standards and regulations of the laws in force.
DANGER
WARNING
D7518

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

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INSTALLATION/REMOVAL OF DRAWER ASSEMBLY
Removal:
A) Loosen off oil delivery tube nut from pump.
B) Loosen SCREW (3), and then unplug CON-
TROL 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 BF5).
D) Loosen SCREW (2), and then slide the
complete drawer assembly out of the com-
bustion head as shown.
E) To insert drawer assembly, reverse the pro-
cedure in items A to D above.
ELECTRODE SETTING
IMPORTANT:
These dimensions must be observed and verified.
NOZZLE PLACEMENT
- Remove the NOZZLE ADAPTER (2) from the DRAWER
ASSEMBLY by loosening the SCREW (1).
- Insert the properNOZZLE into the NOZZLEADAPTER and
tighten securely (Do not over tighten).
- Replace adapter, with nozzle installed, into drawer assem-
bly and secure with screw (1).
IMPORTANT:
The nozzle and the pump pressure must be in accordance with the burner setup chart at page 12.
TURBULATOR SETTING
A) Loosen NUT (1), and then turn SCREW (2) until the
INDEX MARKER (3) is aligned with the correct in-
dex number as per the burner setup chart at page 9.
B) Retighten the RETAINING NUT (1).
MODEL BF3: Zero and three are scale indicators only.
From left to right the first line is 3 and the last line 0.
MODEL BF5: Same as above, except scale indicators
are 0 and 4.
E9327
5/32” or 4 mm
5/32” to 13/64” or 4 to 5 mm
13/64”
5 mm
D6003
S7459
3
2
1
D7520