Riello Riello F10 User manual

BURNERS
MODEL F10
INSTALLATION
MANUAL
RIELLO 40
SERIES
OIL BURNERS
RETROFIT APPLICATIONS ONLY
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.
F10-2000-02 2902554-1

TABLE OF CONTENTS
TECHNICAL DATA ........................................... 1
Dimensions ........................................... 1
Specifications ......................................... 1
OIL BURNER COMPONENTS IDENTIFICATION .................... 2
F10 Burner Components ................................. 2
Serial Number Identification .............................. 2
INITIAL SET-UP ............................................. 2
ASSEMBLY OF AIR TUBE TO BURNER CHASSIS ................... 3
MOUNTING THE BURNER TO BOILER OR FURNACE ............... 3
Method 1- Universal Mounting Flange ....................... 3
Method 2- Semi-flange Collar ............................. 5
Method 3- Pedestal Mount ............................... 5
ELECTRICAL CONNECTIONS .................................. 5
APPLICATION FIELD WIRING .................................. 6
NOZZLE PLACEMENT ........................................ 7
INSERTION/REMOVAL OF DRAWER ASSEMBLY ................... 7
ELECTRODE SETTING ....................................... 8
TURBULATOR SETTING ...................................... 8
OIL LINE CONNECTIONS ..................................... 8
Single Line (Gravity Feed System) ......................... 9
Two Line (Lift System) .................................. 10
PUMP PURGE .............................................. 11
Single Line (Gravity Feed System) ......................... 11
Two Line (Lift System) .................................. 11
SETTING THE AIR ADJUSTMENT PLATE ......................... 12
BURNER SET-UP CHART ..................................... 12
SPARE PARTS .............................................. 14
PRECAUTIONS - CANADA ..................................... 16
PRECAUTIONS - U.S.A ........................................ 17
PARTS LIST
Your Riello 40 F10 burner should include the following parts. Please check to make
sure all parts are present before beginning the installation.
QTY. DESCRIPTION (parts bag)
_
2-
4-
2-
1-
1-
2-
1-
Mounting flange bolts (short)
Semi-flange bolts (long)
Nuts
Chrome nuts
Oil pump connector (supply)
Oil pump connector (return)
Female 1/4" NPT adapter
Male 3/8" NPT adapter
QTY. DESCRIPTION (carton)
1 - Burner chassis with cover
1 - Universal Mounting Flange
2 - Semi-flanges
1 - Mounting gasket
1 - Installation Manual
1 - By-pass plug
1 - 2.5 mm Allen key
(separate carton)
1 - Combustion head
* OEM burners shipped with combustion head mounted.
F10 -I

RIELLO 40 F10
TECHNICAL DATA
!_ B
O
L)
D6012
DIMENSIONS
Inches 10 5/16 12 8 1/32 3 15/16 5 10 7/16
mm 262 305 204 100 127 265
El 10 inch long (254 mm) tubes also available.
SPECIFICATIONS
FUEL: No. 2 Fuel Oil
FIRING RATE: 1.45 to 2.95 GPH 4.7 to 9.5kg/h
EFFECTIVE OUTPUT: 203,000 to 413,000BTU/h 59.5 to 121 kW
51,160 to 104,130 kcal/h
VOLTAGE (Single Phase): 120V 60Hz(+10% -15%)
ABSORBED ELECTRICAL POWER: 264 Watts
MOTOR (rated): 3250rpm Run Current 2.2 AMP
CAPACITOR: 12.5Microfarads260V
PUMP PRESSURE: 130 to 200PSI
PRIMARY CONTROL: RIELLO530SE/C
IGNITION TRANSFORMER: 8kV 16mA
MOUNTING FLANGE DIMENSIONS
I I
MODEL F10 A B
Inches 1 1/4 1/4
mm 32 6
7/16 2 3/16
11 56
5 1/2"-
7 1/2" - 190 mm
8 15/32" - 215 mm D6000
FIO- 1

OIL BURNER COMPONENTS IDENTIFICATION
RIELLO 40 SERIES
F10 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
9. End cone
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
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 - spe-
cific to product code - reset to zero each January 1st.
iYea r of Manufacture _97)_(A)( 851111)_ ( 00025 _Sequence]
IBl-week of manufacture Iburner product code I
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 loosening the three screws securing it. Remove control
box and air tube cover (see page 7).
C) Remove drawer assembly from air tube, insert nozzle and set turbulator
adjustment for specific input required (see pages 7 & 8), then set aside.
D) Mount air tube to burner chassis (see page 3).
F10- 2

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, 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 (see page 7).
D) Tighten the two bolts (3) securely.
$7462
t
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
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.
F10- 3

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.
$7461
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 B at 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).
iJ
D6013
COMBUSTION
CHAMBER
E::Z:Z:Z:Z:_
j .............
D6014
DRY
BASE
BOILER
A
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 appliance mounting bolts using the mounting flange for
proper positioning. Lightly tap the flange with a hammer to form the holes.
F10- 4

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,
items 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
connections 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 ter-
minal and the neutral (white)
wire must be connected to the N
terminal or the primary safety
control will be damaged.
Do not connect either wire to the
(_Terminal.
$7454
F10- 5

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 a R8038A
Honeywell switching relay or equivalent.
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.
IWARNING: DO NOT activate burner until proper oil line connections have beenmade, or failure of the pump shaft seal may occur.
APPLICATION FIELD WIRING
DIRECT LINE VOLTAGE LOW VOLTAGE
I Eli FUSE 15A
W I _ O ,/LINE SAFETY
o/ SWITCH
_1 _-_,_ /OPERATING
_1 __O/UMiTSwITCH
/il SAFTET_wiTCH
FUSE15A
o/ LINE SAFETY
_ F _---_'f SwiTCH
ZC_ _ _,%6/ OPERATING
OD _" __f LiMITSWiTCH
-r _ S _)/ SAFETY
1..- z ::z:/LIMIT SWITCH
t
<
uJ
]?WITCHING RELAY
FACTORY
WIRED
SUB-BASE VAL
2
DI
K
_1 CAP OR
z
D5995
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 (O) on the SUB-BASE. Should lockout
occur the 530SE CONTROL BOX will supply a power source of 120Vac to the con-
nection terminal. The maximum allowable current draw on this terminal (4) is 1 Amp.
IWARNING: If a neutral or ground lead is attached to this terminal, the CONTROLBOX on the burner will be damaged should lockout occur.
F10- 6

NOZZLE PLACEMENT
A) Determine the proper firing rate
for the boiler or furnace unit, consid-
ering the specific application, then
use the Burner Set-up chart on page
12 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). S7459
C) Insert the proper NOZZLE into the
NOZZLE ADAPTER and tighten securely (Do not overtighten).
D) Replace adapter, with nozzle installed, into drawer assembly and secure with
screw (1).
INSERTION/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.
$7460
F10- 7

ELECTRODE SETTING
IMPORTANT:
THESE DIMENSIONS MUST BE OBSERVED AND VERIFIED.
D6003
5/32" or 4 mm
5/32" to 13/64" or 4 to 5_ ....................
-I--
tt_
TURBULATOR SETTING
A) Loosen NUT (1), then turn SCREW
(2) until the INDEX MARKER (3) is
aligned with the correct index number
as per the Burner Set-up chart, on
page 12.
B) Retighten the RETAINING NUT (1).
NOTE: Zero and five are scale indica-
tors only. From left to right, the first line
is 5 and the last line 0.
5111111
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.
F10- 8