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.