Riello F3 User manual

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
1
MODEL F3 & F5
INSTALLATION
MANUAL
RIELLO 40
SERIES
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.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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TABLE OF CONTECT
TECHNICAL DATA -Model F3................................................................................…..3
TECHNICAL DATA –Model F5 .....................................................................................4
OIL BURNER COMPONENT IDENTIFICATION.........................................................5
Burner Components .......................................................................................................5
Serial Number Identification..........................................................................................5
INITIAL SET-UP ..............................................................................................................5
ASSEMBLY OF AIR TUBE TO BURNER CHASSIS....................................................6
MOUNTING BURNER TO BOILER OR FURNACE................................................6 -8
Method 1-Universal Mounting Flange...........................................................................7
Method 2-Semi-flange Collar ........................................................................................8
Method 3-Pedestal Mount ..............................................................................................8
ELECTRICAL CONNECTIONS......................................................................................8
APPLICATION FIELD WIRING.....................................................................................9
NOZZLE PLACEMENT.................................................................................................10
INSERTION / REMOVAL OF DRAWER ASSEMBLY...............................................10
ELECTRODE SETTING.................................................................................................11
TURBULATOR SETTING.............................................................................................11
OIL LINE CONNECTIONS.....................................................................................11 -13
Single Line (Gravity Feed) ..........................................................................................12
Two Line (Lift System).........................................................................................12 -13
PUMP PURGE..........................................................................................................13 -14
Single Line (Gravity System) ......................................................................................13
Two Line (Lift System)................................................................................................14
SETTING THE AIR ADJUSTMENT PLATE................................................................14
BURNER ADJUSTMENT TABLES ..............................................................................15
AMULET INSTALLATION INSTRUCTIONS.............................................................16
INSTALLATION PRECAUTIONS................................................................................17
EXPLODED SPARE PARTS LIST................................................................................18
SPARE PARTS LIST ......................................................................................................19
PACKAGE LIST
Your Riello 40 burner should include the following parts. Please check to make sure all parts are present before
beginning the installation.
QTY. DESCRIPTION (parts bag) QTY. DESCRIPTION (carton)
2 -Mounting flange bolts (short) 1 -Burner chassis with cover
2 -Semi-flange bolts (long) 1 -Universal Mounting Flange
4 -Nuts 2 -Semi-flanges
2 -Chrome nuts 1 -Mounting gasket
1 -Oil pump connector (supply) 1 -Installation Manual
1 -Oil pump connector (return) 1-By-pass plug
1 -Female ¼” NPT adapter
1 -Male 3/8” NPT adapter * (Separate carton)
1 -2.5 mm Allen key 1 -Combustion Head
* OEM burners shipped with combustion head mounted

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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B
A
E
E1 F
C
D
RIELLO 40 F3 TECHNICAL DATA
DIMENSIONS
MODEL F3 ABCDEF
Inches 8 15/32 9 59/64 6 15/32 3 1/2 68 29/32
mm 215 252 164 89 152 226
E1: 10-inch long (254mm) tubes are also available.
SPECIFICATIONS
FUEL: No. 2 Fuel Oil
FIRING RATE: 0.50 to 0.95 US GPH
EFFECTIVE OUTPUT: 70,000 to 133,000 BTU/h
VOLTAGE (Single Phase): 120V 60Hz (+ 10% -15%)
ABSORBED ELECTRICAL POWER: 264 Watts
MOTOR (rated): 3250 rpm Run Current 2.2 AMP
CAPACITOR: 12.5 Microfarads
PUMP PRESSURE: 130 to 200 psig
PRIMARY CONTROL: RIELLO 530 SE/C
IGNITION TRANSFORMER: 8kV 16mA
MOUNTING FLANGE DIMENSIONS
MODEL F3 ABCD
Inch 1 1/4 1/4 7/16 2 3/16
mm 32 611 56
30º
45º
60º B
C
3 31/32" - 101mm
5 1/2" - 140mm
7 1/2" - 190mm
D
7 3/32" - 180mm
A

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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B
A
E
E1 F
C
D
RIELLO 40 F5 TECHNICAL DATA
DIMENSIONS
MODEL F5 ABCDEF
Inches 9 11/64 10 11/16 7 3/32 3 1/2 69 13/32
mm 233 272 180 89 152 239
E1: 10-inch long (254mm) tubes are also available.
SPECIFICATIONS
FUEL: No. 2 Fuel Oil
FIRING RATE: 0.75 to 1.65 US GPH
EFFECTIVE OUTPUT: 105,000 to 231,000 BTU/h
VOLTAGE (Single Phase): 120V 60Hz (+ 10% -15%)
ABSORBED ELECTRICAL POWER: 175 Watts
MOTOR (rated): 3250 rpm -2.2 AMP
CAPACITOR: 12.5 Microfarads
PUMP PRESSURE: 130 to 200 psig
PRIMARY CONTROL: RIELLO 530 SE/C
IGNITION TRANSFORMER: 8kV 16mA
MOUNTING FLANGE DIMENSIONS
MODEL
F5 ABCD
Inch 1 1/4 1/4 7/16 2 3/16
mm 32 611 56
30º
45º
60º B
C
3 31/32" - 101mm
5 1/2" - 140mm
7 1/2" - 190mm
8 15/32" - 215mm
D
7 3/32" - 180mm
A

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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OIL BURNER COMPONENTS IDENTIFICATION
RIELLO 40 SERIES
F3 & F5 BURNER COMPONENTS
1.
Lockout indicator lamp and reset button 11. Semi Flange
2. Primary control 12. Turbulator adjustment screw
3. Primary control sub-base 13. Air tube cover
4. Pump pressure regulator 14. Coil
5. Motor 15. Vacuum gauge port
6. Air adjustment fixing screws 16. Pressure gauge and bleeder port
7. Hydraulic air shutter 17. Return fuel line port
8. Capacitor 18. Supply fuel line port
9. Hydraulic Jack (optional) 19. Capillary tube
10. Combustion Head 20. Mounting flange with gasket
SERIAL NUMBER IDENTIFICATION
The Riello 15 character serial number, example, 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 1 for each burner produced –specific to product code –reset to zero each January 1st.
(99) (A) (811111) (00025)
Year of manufacture BI-week of manufacture Burner product code Increment
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 adjustment for specific input
required (see pages 8 & 9), then set aside.
D) Mount air tube to burner chassis (see next page).
1
2
3
4
5
6
7
8
9
20 19
18 17 16
15
141312
11
10

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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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 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, install the required nozzle (see page 10) 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 PATE (5) with the two holes on the BURNER 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 10).
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.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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METHOD 1 –UNIVERSAL MOUNTING FLANGE
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 appliance 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 (9) is properly positioned so the outside edge of the
END CONE will be at least ¼ inch (6.5mm) back from the inside wall of the refractory of the combustion
chamber (see dimension B above). 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 insetting 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 (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 ¼” (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
hammer to form the holes.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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4
5
3
1
2
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 ¼ inch (6.5mm) 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.
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 WILL DAMAGE THE
END CONE.
ELECTRICAL CONNECTIONS
It is advisable to leave the control box off the sub-base while completing 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
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
The burner may be controlled using either a DIRECT LINE VOLTAGE control circuit (120V AC 60 cycle) OR
a LOW VOLTAGE control switching relay.
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.
WARNING: DO NOT activate burner until proper oil line connections have been made, or failure of the
pump shaft seal may occur.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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APPLICATION FIELD WIRING
REMOTE SENSING OF SAFETY LOCKOUT: The SAFETY SWITCH in the 530SE 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 530SE 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.
WARNING: If a neutral or ground lead is attached to this terminal, the CONTROL BOX on
the burner will be damaged should lockout occur.
N
•
L
HOT LINE (BLACK)
EARTH GROUND (GREEN)
NEUTRAL (WHITE)
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
N
•
L
T
T
NEUTRAL (WHITE) HOT LINE (BLACK)
EARTH GROUND (GREEN)
LINE SAFETY
SWITCH
OPERATING
LIMIT SWITCH
SAFETY
LIMIT SWITCH
FUSE 15A
24
V
AC
120
V
AC
120
V
AC
DIRECT LINE
VOLTAGE LOW VOLTAGE
TRANSFORMER &
SWITCHING RELAY
1 2 43 765 98
N
•
L
MOTOR
CAPACITOR
BLACK
COIL
BLUE
BROWN BLACK
VALVE
BLUE
WHITE
BLACK
BROWN
WHITE
WHITE
RIELLO
FACTORY
WIRED SUB
BASE
FIELD
WIRING

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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NOZZLE PLACEMENT
A) Determine the proper firing rate for the boiler or furnace 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 off oil 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.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
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04
4 0
3
2
1
ELECTRODE SETTING
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 right the first line is 3and the last line 0.
MODEL F5: Same as above, except, scale indicators are 0
and 4.
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 thePRESSURE PORT (8)
for pressure readings. Two PIPE CONNECTORS (6) are supplied with the burner for connection to either a single or
two-line system. Also supplied are two ADAPTORS (3), two female ¼” 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 adapters, and can be safely connected to the pump ports. An
NPT (metric) adapter must be used when connecting other gauge models.
1
4
3
2
RIELLO
P
V
4
7
8
6
5
5/32" - 4mm
13/64"
5mm
5/64" to 7/64" or 2 to2.5mm
IMPORTANT: THIS DIMENSIONS MUST BE OBSERVED AND VERIFIED.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
12
H
P
NOTE: Do not exceed pipe lengths indicated in
chart.
H
P
H
NOTE: Do not exceed pipe lengths indicated in
chart.
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 MFT MFT M
1.5 0.5 33 10 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.
TWO LINE (LIFT SYSTEM)
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-mm hexagonal key provided with
the by-pass plug is to be used to install the plug. DO
NOT use an Imperial 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 above.
2 LINE (LIFT) SYSTEM-PIPE
LENGTHS
H3/8” OD 1/2” OD
FT MFT MFT M
0.0 0.0 115 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

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
13
RIELLO
P
V
BC
A
To install the by-pass plug:
1) Remove the return plug (7)
2) Install the by-pass plug (4) using the 2.5 mm 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.
WARNING: Pipe dope or Teflon tapes are NOT to be used on any direct oil connection to the fuel pump.
WARNING: The height ‘P’ in Pipe Length Charts should not exceed 13 feet (4 m).
WARNING: 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.
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. Loosen the bleeder valve (A) until oil flows out.Tighten the bleeder
valve securely and startburner.
II. When bleeding the pump by pressure:
1) Loosen the bleeder valve (A).
2) Disconnect nozzle oil supply line at the pump nozzleport (B).
3) Attach a flexible plastic tube 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 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 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 of unburned oil in the combustion chamber
creating a hazardous situation upon burner startup.

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14
0
1
2
3
4
5
6
5
4
3
2
1
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 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 WILL OCCUR.
SETTING THE AIR ADJUSTMENT PLATE
A) The hydraulic AIR SHUTTER (1) is operated by the HYDRAULIC JACK (6), assuring complete opening
of the combustion air intake. Regulation of the combustion airflow is made by adjustment of the manual
AIR ADJUSTMENT PLATE (4) after loosening the FIXING SCREWS (3 & 5). The initial setting of the air
adjustment plate should be made according to Column 5 in the Burner Setup Charts on page 15.
B) The proper number on the manual AIR ADJUSTMENT
PLATE (4) should line up with the SETTING
INDICATOR (2) on the fan housing cover. Once set, the
air adjustment plate should be secured in place by
tightening SCREW 3 and 5. Manually open and release
the hydraulic shutter to ensure it has free movement.
C) The final position of the air adjustment plate will
varyon each installation. Use instruments to establish
the proper setting for maximum CO2and a smoke reading of
zero.
NOTE: Variations in flue gas, smoke, CO2and 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.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
15
BURNER ADJUSTMENT TABLES
NON-RETROFIT APPLICATIONS
If this burner is being installed in a packaged unit (i.e. Burner comes with a boileror 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
MODEL F5 BURNER SETUP CHART
1
ACTUAL FIRING
RATE 5% ±
2
NOZZLE
SIZE
3
PUMP
PRESSURE
US GPH GPH PSI BAR
4
TURBULATOR
SETTING
5
AIR DAMPER
SETTING
0.75 .60 x 60/ 80º 145 10 0.0 2.25
0.85 .65 x 60/ 80º 145 10 0.5 2.5
1.00 .85 x 60/ 80º 145 10 1.0 2.75
1.10 1.00 X 60/ 80° 145 10 2.0 3.0
1.25 1.10 x 60/ 80º 145 10 2.5 3.5
1.50 1.25 x 60/ 80º 145 10 3.0 4.25
1.65 1.35 X 60/ 80° 145 10 4.0 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 B139 or NFPA #31).
1
ACTUAL FIRING
RATE 5% ±
2
NOZZLE
SIZE
3
PUMP
PRESSURE
US GPH GPH PSI BAR
4
TURBULATOR
SETTING
5
AIR DAMPER
SETTING
0.50 .40 x 60º/80º 160 11.0 0.0 2.3
0.60 .50 x 60º/80º 150 10.4 0.5 2.7
0.75 .60 x 60º/80º 150 10.4 1.5 3.4
0.80 .65 x 60º/80º 150 10.4 2.0 3.6
0.95 .75 x 60º/80º 160 11.0 3.0 4.3

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
16
AMULET INSTALLATION INSTRUCTIONS
(Required on some models)
The amulets provided have been selected by Riello to protect the combustion tube from hot 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 diameter.
The amulet 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 amulet over the
combustion tube. Excessive force can result in a broken amulet!
If the amulet 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 diagram below shows the proper position of the amulet after installation.
air tube
AMULET HELPS
PREVENT HOT
GASES FROM
TRAVELLING
DOWN AIR
TUBE
air tube
increase in
pressure down air
tube due to
increase in
combustion
chamber pressure
increase in pressure down air
tube due to increase in
combustion chamber
pressure
tapered combustion
chamber causes
increase in pressure
inside
LOW PRESSURE
HIGH PRESSURE
AMULET
NO AMULET
increase in pressure down air
tube due to increase in
combustion chamber
pressure
tapered combustion
chamber causes
increase in pressure
inside
LOW PRESSURE
HIGH PRESSURE
flue
gases
heat
heat
flue
gases
heat
heat
Amulet shown in
the flush
mounted position
Head Receeded
1/4 inch max.

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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 sufficient
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 connected
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 EXTINGUSHER
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.

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
18
5 6 7 8 12V .26A 12V .25A TRPH4-24 97 .08. 1 aw 115V 60/60HZ
ATCFROST
50
49
SPARE PARTS
38

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
19
RIELLO SPARE PARTS LIST F3 & F5
•Indicates applicable model for each part.
No CODE F3 F5 DESCRIPTION No CODE F3 F5 DESCRIPTION
13007232
•Burner Back Cover 26 C7001029 ••Primary Control
2
3007233 •Burner Back Cover 27 3005854 ••Semi Flange (2 Required)
3006992 ••Pipe Connector Supply 28 3005855 ••Universal Mounting Flange
33006571 ••3/8” NPT/Metric Adapter –Male 29 3005856 ••Mounting Gasket
43006993 ••Pipe Connector Return C7001058 •Capillary Tube (if used)
53005847 ••¼” NPT/Metric Adapter –Female 30 C7001059 •Capillary Tube (if used)
63007077 ••Crushable Metal Washer 3/8” ID 31 3006911 ••Hydraulic Jack (if used)
73007568 ••Bleeder 32 3000878 ••Hydraulic Air Shutter (if used)
83007028 ••O-Ring –Pump Pressure Regulator 33 3007204 ••Manual Air Shutter
93007202 ••Regulator Screw 3007207 •Air Intake Housing
10 C7010002 ••O-Ring –Pump Cover (3007162) 34 3007208 •Air Intake Housing
11 3005719 ••Pump Screen 35 3005844 ••Capacitor 12.5µF
12 3006925 ••Valve Stem 36 3005708 ••Fan
13 3007203 ••Valve Stem Plate C6950050 •Acoustic Liner
14 3007029 ••O-Ring -Valve Stem Upper 37 3007320 •Acoustic Liner
15 3007156 ••O-Ring -Valve Stem Lower 3007221 •Chassis Front Plate
16 3007268 ••Nozzle Outlet Fitting 38 3007222 •Chassis Front Plate
17 3007087 ••Crushable Metal Washer 5/8” ID
18 3002278 ••Primary Control Sub-Base OPTIONAL
19 3006553 ••Coil U-Bracket and Knurled Nut 49 C7001033 ••Amulet –Cerafelt Sleeve Kit
20 3002279 ••Coil 50 C7001085 ••AL1008 24V Switching relay kit
21 3007802 ••Pump 50 C5830011 ••AL1008 24V Switching relay
22 3000443 ••Pump Drive Key 50 C7001084 ••AL1009 Post purge device kit
23 3005843 ••Motor 120VOLT 60Hz
3007315 •Air Tube Cover
24
3007316 •Air Tube Cover 51 2623141 ••Capillary port plug
25 3002280 ••Photocell 52 3000932 ••Adjustable Steel Flange
VSBT COMBUSTION HEAD SHORT COMBUSTION HEAD
3948876 •VSBT Combustion Head 3” 3948873 •Short Combustion Head 6” (271T1)
40
3948976 •VSBT Combustion Head 3” 40 3948973 •Short Combustion Head 6” (271T1)
3006968 •Turbulator Disc 3006968 •Turbulator Disc
41
3006977 •Turbulator Disc 41 3006977 •Turbulator Disc
42 3006966 ••Electrode Support 42 3006966 ••Electrode Support
43 3006965 ••Nozzle Adapter 43 3006965 ••Nozzle Adapter
3008627 •Nozzle Oil Tube 3006969 •Nozzle Oil Tube –Short
44
3008629 •Nozzle Oil Tube 44 3006973 •Nozzle Oil Tube –Short
3008633 •Regulator Assembly 3006324 •Regulator Assembly –Short
45
3008634 •Regulator Assembly 45 3006323 •Regulator Assembly –Short
3008630 •Electrode Assembly 3006330 •Electrode Assembly –Short
46
3008631 •Electrode Assembly 46 3006329 •Electrode Assembly –Short
47 3005869 ••Electrode Porcelain 47 3005869 ••Electrode Porcelain
3008623 •Air Tube only 3007592 •Air Tube only
48
3008626 •Air Tube only 48 3007594 •Air Tube only
8 7/8" COMBUSTION HEAD LONG COMBUSTION HEAD
3948877 •Combustion Head 8 7/8" 3948874 •Long Combustion Head 10” (271T2)
40
3948975 •Combustion Head 8 7/8" 40 3948974 •Long Combustion Head 10” (271T2)
3006968 •Turbulator Disc 3006968 •Turbulator Disc
41
3006977 •Turbulator Disc 41 3006977 •Turbulator Disc
42 3006966 ••Electrode Support 42 3006966 ••Electrode Support
43 3006965 ••Nozzle Adapter 43 3006965 ••Nozzle Adapter
3008790 •Nozzle Oil Tube 3006970 •Nozzle Oil Tube –Long
44
3008628 •Nozzle Oil Tube 44 3006974 •Nozzle Oil Tube –Long
3008846 •Regulator Assembly 3005867 •Regulator Assembly –Long
45
3008635 •Regulator Assembly 45 3005878 •Regulator Assembly –Long
3008789 •Electrode Assembly 3005870 •Electrode Assembly –Long
46
3008632 •Electrode Assembly 46 3005880 •Electrode Assembly –Long
47 3005869 ••Electrode Porcelain47 3005869 ••Electrode Porcelain
3008788 •Air Tube only 3007593 •Air Tube only
48
3008625 •Air Tube only 48 3007595 •Air Tube only

C6501010 STANDARD F3-5 MANUAL Rev. 3-2 10/12/2006
20
35 Pond Park Rd.
Hingham, MA 02043
Phone: 781-749-
8292
Toll Free: 800-992-
7637
Fax: [phone]
2165 Meadowpine Blvd.
Mississauga,On L5H 3R2
Phone: 905-542-
0303
Toll Free: 800-387-
3898
Fax: [phone]
BURNER START-UP FORM *
Burner S/N. or
Model: Appliance:
Installer name:
Company: Installation date:
Address:
Phone: Fax:
Owner Name:
Address:
Phone: E-mail:
Burner Start-up Info (OIL) Burner Start-up Info (GAS)
Nozzle Info: Gas Supply Pressure:
Pump Pressure: Pump
pressure:
Air Setting: Turbulator
setting: Air Setting: Head Setting:
Draft Overfire: Draft
breech:
Draft Overfire: Draft
breech:
CO2:
CO:
O2:
CO2:CO: O2:
Smoke density: (Bacharach) Manifold pressure:
Single
Line:
Two
Lines:
Ionization Reading
(µAd.c.): Input BTU/Hr:
*This form was designed and provided in the installation manual for reference and also for providing
technical information which can be faxed or mailed to our technical hot-line coordinator when technical
assistance is required. Please complete this form, fax it or mail it at the address/fax above, or send an e-
mail with the information listed below to: [email protected]