Riello R35 Series User manual

OIL BURNER
R35 SERIES
INSTALLATION MANUAL
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 in this manual.
C6501016 29-Mar-11 STANDARD R35 MANUAL REV 1-3
.DOC

1
TABLE OF CONTENTS
PAGE
BURNER MODEL IDENTIFICATION………………………………………….. 2
TECHNICAL DATA: DIMENSIONS………………………………………….. 3
SPECIFICATIONS……………………………………...
……..
4
COMPONENT IDENTIFICATION……………………………………………… 4
MOUNTING THE BURNER…………………………………………………….. 5
ELECTRICAL CONNECTIONS………………………………………………… 6
FIELD WIRING…………………………………………………………………... 7
REMOTE SENSING OF SAFETY LOCKOUT SWITCH………………………. 8
REMOVAL OF DRAWER ASSEMBLY………………………………………... 9
INSTALLING THE NOZZLE…………………………………………………… 9
ELECTRODE ADJUSTMENT………………………………………………….. 9
OIL LINE CONNECTIONS: BY-PASS PLUG INSTALLATION…………… 10
SINGLE LINE SYSTEM………………………. 10
TWO LINE SYSTEM………………………….. 11
PUMP PURGE……………………………………………………………………. 12
WORKING FIELD……………………………………………………………….. 13
BURNER SET-UP: TURBULATOR SETTING……………………………… 13
AIR DAMPER SETTING……………………………….. 13
SET-UP CHARTS……………………………………….. 14
RECOMMENDED NOZZLES…………………………... 14
AMULET INSTALLATION INSTRUCTIONS……..…………………………... 15
SPARE PARTS EXPLODED VIEW……………………………………………... 16
SPARE PARTS LIST……………………………………………………………... 17
INSTALLATION PRECAUTION:
…………………………………………….
18
CARTON CONTENTS
Your RIELLO 35 burner carton includes the following parts. Please check to make sure
all parts are present before beginning the installation.
1 – Burner
1 – Mounting Flange
1 – Mounting Gasket
1 – By-pass Plug (attached to burner)

2
SERVICE TOOLS REQUIRED
1 – No 1 Philips Screwdriver
1 - No. 2 Philips Screwdriver
1 – No. 2 Slotted Screwdriver
1 – 1 inch Adjustable Wrench
4 – Allen Keys: 2.5 mm – Pump By-pass Plug
1/8 inch – Pump Pressure Regulator
5/32 inch – Pump – Cover & Mounting Bolts, Blower Fan
7/32 inch – Adjustable Flange Bolt
BURNER MODEL IDENTIFICATION
HOW TO READ BURNER MODEL IDENTIFICATION
EXAMPLE
R35 . 3 . 03 . R . 0
R35.3
MODEL CODE MODEL CODE
R35.3.03.R.0 C8511205 R35.3.03.0.R C8511200
R35.3.04.R.0 C8511206 R35.3.04.0.R C8511201
R35.3.05.R.0 C8511207 R35.3.05.0.R C8511202
R35.3.07.R.0 C8511208 R35.3.07.0.R C8511203
R35.3.10.R.0 C8511209 R35.3.10.0.R C8511204
R35.5
MODEL CODE MODEL CODE
R35.5.03.R.0 C8512205 R35.5.03.0.R C8512200
R35.5.04.R.0 C8512206 R35.5.04.0.R C8512201
R35.5.05.R.0 C8512207 R35.5.05.0.R C8512202
R35.5.07.R.0 C8512208 R35.5.07.0.R C8512203
R35.5.10.R.0 C8512209 R35.5.10.0.R C8512204
Remote Sensing
R= Standard on 535SE Control Box
0= Not available on 536SE Control Box
24 volt Thermostat Terminals
R= Standard on 536SE Control Box
0
= Not Available on 535SE Control Box
Useable Air Tube Length
See TABLE A on p
age 3.
Firing Rate Range
3= 0.60 – 1.10 GPH
5
= 0.75
–
1.60 GPH

3
F D A
E
Ø B
C
TECHNICAL DATA
DIMENSIONS – FIG.1
A B C D E F
3 1/2 8 5/16 8 5/16 11 7/8 9 3/8
Inches
mm
See
Tab. A 89 211 211 301 237
DIMENSIONS – FIG.2
A B C D E F
3 5/8 5 1/2 7 1/2 8 7/16 7 1/16 7/16
Inches
mm 92 140 190 215 180 11.2
TABLE A USEABLE AIR TUBE LENGTH
R35.3 R35.5BURNER
MODEL Inches mm Inches mm
.03 3 ¼ 82 3 1/8 80
.04 4 7/16 112 4 5/16 110
* .05 5 11/16 145 5 5/8 143
* .07 7 ¾ 196 7 5/8 194
* .10 10 1/8 257 10 255
* length can be increased approximately
1” by using available fixed flange.
Note: Useable length includes 4mm standard gasket
- Models .03 & .04 fixed flange standard
- Models .05, .07 & .10 adjustable flange standard
A
B
C
D
E
30º
45º
60º
F
FIG. 1
FIG. 2

4
SPECIFICATIONS R35.3 R35.5
FUEL No. 2 Fuel Oil
Gph 0.60 – 1.10 0.75 – 1.60
FIRING RATE Kg/h 1.89 – 3.5 2.4 – 5.0
Btu/h 81,200 – 154,000 105,200 – 224,000
EFECTIVE OUTPUT kW 23.8 - 45 30.8 – 65.5
VOLTAGE Single Phase 120V 60Hz (+10% - 15%)
POWER CONSUMPTION 130 W 140 W
MOTOR (Rated) 3250 rpm
MOTOR CURRENT (Rated) 2.2 A 2.2 A
CAPACITOR 10 µF – 260 V
PUMP PRESSURE (max.) 200 PSI
PRIMARY CONTROL 536 SE – 535 SE
IGNITION TRANSFORMER 8 kV 16 mA
COMPONENT IDENTIFICATION
1. Thermostat connection terminals
(536 only)
10. Air tube
2. Vacuum gauge connection port 11. Air damper adjustment screw
3. Inlet fuel line port 12. Photocell
4. Return fuel line port 13. Drawer assembly
5. Bleeder / Pressure gauge connection port 14. Lockout lamp ( 535 only ) &
Reset button
6. Pump pressure regulator adj. Screw 15. Primary safety control
7. Electrical enclosure 16. Fuel pump
8. Capacitor (hidden) 17. Motor
9. Mounting flange & gasket
12 13 14
15
2
3
4
16
17
5 6 7
8
9
10111
FIG. 3

5
MOUNTING THE BURNER
There are three possible methods to mount the burner, depending on the individual
application. These are:
1.) Fixed UNIVERSAL FLANGE bolted to the boiler/furnace unit.
2.) ADJUSTABLE FLANGE bolted to the boiler / furnace unit.
3.) ADJUSTABLE FLANGE or fixed UNIVERSAL FLANGE mounted directly to optional
Pedestal kit (C7001022) must be ordered separately.
METHOD 1. (ref. FIG. 5)
A.) Remove the 4 screws (1) from the burner
chassis. Position the UNIVERSAL
MOUNTING FLANGE (2) with
countersunk mounting holes (4) facing
away from burner. Insert the 4 screws (1)
through the countersunk mounting holes
and secure in place.
B.) Position MOUNTING GASKET (3)
between the MOUNTING FLANGE and
the appliance plate. Line up the holes in the
MOUNTING FLANGE with the studs on
the appliance mounting plate and securely
bolt in place.
A
B B
A
FIG. 4
DRY
BASE BOILER
COMBUSTION
CHAMBER
FIG. 5

6
1 2
METHOD 2. (ref. FIG. 6)
A.) Secure the ADJUSTABLE FLANGE
(1) to the burner AIR TUBE by
tightening the bolt (2). Be sure that
the ADJUSTABLE COLLAR is
properly positioned so the outside
edge of the END CONE will be at
least ¼ inch (6.5 mm) back from the
inside wall of the refractory of the
combustion chamber (see dimension
B in FIG. 4 above). The measured
length (A), is to the face of the
MOUNTING GASKET.
B.) Secure the burner to the appliance as
per METHOD 1-B.
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 and 2.
SERIAL NUMBER IDENTIFICATION
The Riello 15 character serial number, example, 97 A 8511111 00025, is identified as follows: 97 = 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 1
st
.
(97) (A) (851111) (00025)
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 COULD
DAMAGE THE END CONE.
FIG. 6
Year of Manufacture BI-week of manufacture Burner product code Sequence

7
ELECTRICAL CONNECTIONS
To gain access to the line voltage terminals on the primary safety control follow items A and
B below.
A.) Remove drawer assembly from the burner.
B.) Remove the electrical enclosure by removing the three screws. FIG. 3 (7).
C.) Make electrical connections to burner as shown in FIG. 7.
D.) Replace the electrical enclosure over the terminals on the control box and secure using
three screws.
1. Wire Access Hole (Use BX connector)
2. Ground Terminal (Green/Copper Wire)
3. Line (Phase) Terminal (Black Wire)
4. Neutral Terminal (White Wire)
5. Remote Lockout Terminal (535 SE Only)
6. Control Box Mounting Screw
7. 24 V Thermostat Terminals (536 SE Only)
8. Power Supply

8
FIELD WIRING
Burner operation is controlled by using a low voltage control (24 Vac) with the standard
536SE CONTROL BOX. On some OEM applications, burner operation may be controlled by
using a line voltage (120 Vac) control with the 535SE CONTROL BOX.
The 536SE CONTROL BOX can also be used in a line voltage circuit, by using a WIRE
JUMPER between the 24 V thermostat terminals on the 536SE CONTROL BOX.
Using the appropriate drawing below and on the next page, complete the required field
application wiring to control the burner. All wiring must be done in accordance with local
codes or, in the absence of local codes, with the National Electrical Code ANSI/NFPA 70-
1990 and the CSA Electrical Code.
536SE CONTROL BOX
M
F F
M
T
T
Photocell
Oil valve
Motor
Capacitor
Black
White
Blue
CONTROL BOX 536SE
Ground
Regulating thermostat
(24V 0.2A)
Limit thermostat
15A max.
Switch with fuse
Neutral
LN
120V ~ 60Hz
WARNING
Do not exchange neutral
with phase.
CARRIED-OUT IN
THE FACTORY
FIELD WIRING
FIG. 8

9
535SE CONTROL BOX
REMOTE SENSING OF SAFETY LOCKOUT SWITCH 535SE
CONTROL BOX
The SAFETY SWITCH on the 535SE CONTROL BOX is equipped with a contact allowing
remote sensing of burner lockout. The electrical connection is located on the CONTROL
BOX terminal ⊗FIG. 7 (5) as indicated. Should burner lockout occur, the 535SE CONTROL
BOX will supply a power source of 120 Vac to the connection terminal.
NOTE: The maximum allowable current draw on this terminal (5) is 1 A.
WARNING: The terminal ⊗FIG. 7 (5) is to be used only for the connection of a remote
sensing device. If a neutral or ground lead is connected to this terminal, the CONTROL BOX
on the burner will be damaged should lockout occur.
M
F F
M
T
Photocell
Oil valve
Motor
Capacitor
Black
White
Blue
CONTROL BOX
535SE
Ground
Limit thermostat
15A max.
Switch with fuse
Neutral
LN
120V ~ 60Hz
WARNING
Do not exchange neutral
with phase.
CARRIED-OUT IN
THE FACTORY
T
Regulating
thermostat
Remote lockout lamp
FIELD WIRING
FIG. 9