Riello 40 F3 Technical data

RIELLO 40 SERIES
MODELS 40 F3 & F5
EQUIPPED WITH ELECTRONIC AIR SHUTTER
INSTALLATION & OPERATING
MANUAL
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.
C6501000 F3-F5 I-O manual Rev4_3
1
TABLE OF CONTENTS
TECHNICAL DATA - Model F3 ...................................................................................... 3
TECHNICAL DATA – Model F5 ..................................................................................... 4
OIL BURNER COMPONENT IDENTIFICATION......................................................... 5
Serial Number Identification.............................................................................................. 5
INITIAL SET-UP .............................................................................................................. 5
ASSEMBLY OF AIR TUBE TO BURNER CHASSIS .................................................... 6
MOUNTING BURNER TO BOILER OR FURNACE..................................................... 6
Method 1-Universal Mounting Flange ............................................................................... 7
Method 2-Semi- flange Collar ............................................................................................ 7
Method 3-Pedestal Mount .................................................................................................. 8
FACTORY WIRING ......................................................................................................... 8
APPLICATION FIELD WIRING ..................................................................................... 9
NOZZLE PLACEMENT ................................................................................................. 10
INSERTION/REMOVAL OF DRAWER ASSEMBLY ................................................. 10
ELECTRODE SETTING................................................................................................. 11
TURBULATOR SETTING ............................................................................................. 11
PUMP CONNECTIONS AND PORT IDENTIFICATION............................................ 11
Single Line (Gravity Feed) .............................................................................................. 12
Two Line (Lift System) .................................................................................................... 12
PUMP PURGE................................................................................................................. 13
Single Line (Gravity System) .......................................................................................... 13
Two Line (Lift System) .................................................................................................... 14
SETTING THE AIR ADJUSTMENT PLATE................................................................ 14
BURNER ADJUSTMENT TABLES .............................................................................. 15
AMULET INSTALLATION INSTRUCTIONS............................................................. 16
SEQUENCE OF OPERATION................................................................................ 17&18
EXPLODED PARTS VIEW ............................................................................................ 19
PARTS LIST.................................................................................................................... 20
START UP FORM .......................................................................................................... 21
INSTALLATION PRECAUTIONS................................................................................ 22
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)
2Mounting flange bolts (short)
2Semi-flange bolts (long)
4Nuts
2Chrome nuts
1Oil pump connector (supply)
1Oil pump connector (return)
1Female ¼” NPT adapter
1Male 3/8” NPT adapter
12.5 mm Allen key
* OEM burners shipped with combustion head mounted
112111-
C6501000 F3-F5 I-O manual Rev4_3
Burner chassis with cover
Universal Mounting Flange
Semi-flanges
Mounting gasket
Installation Manual
By-pass plug
* (Separate carton)
1Combustion Head
2
RIELLO 40 F3 TECHNICAL DATA
E
E1
B
F
D
A
C
DIMENSIONS
MODEL F3
A
B
C
8
15/32
9
59/64
6
15/32
Inches
215
252
164
mm
E1: 10-inch long (254mm) tubes are also available.
D
E
F
3 1/2
89
6
152
8 29/32
226
SPECIFICATIONS
NO heavier than # 2 FUEL OIL
0.50 to 0.95 US GPH
70,000 to 133,000 BTU/h
120V 60Hz (+ 10% - 15%)
155 Watts
3250 rpm Run Current 2.2 AMP
12.5 Microfarads
130 to 200 psig
RIELLO 530 SE/C
8Kv 16mA
60º 45º
30º
B
A
MOUNTING FLANGE DIMENSIONS
MODEL F3
Inch
mm
A
B
C
D
1 1/4
32
1/4
6
7/16
11
2 3/16
56
C
D
7 3/32" - 180mm
FUEL:
FIRING RATE:
EFFECTIVE OUTPUT:
VOLTAGE (Single Phase):
ABSORBED ELECTRICAL POWER:
MOTOR (rated):
CAPACITOR:
PUMP PRESSURE:
PRIMARY CONTROL:
IGNITION TRANSFORMER:
3 31/32" - 101mm
5 1/2" - 140mm
7 1/2" - 190mm
8 15/32" - 215mm
C6501000 F3-F5 I-O manual Rev4_3
3
RIELLO 40 F5 TECHNICAL DATA
E
E1
B
F
D
A
C
DIMENSIONS
MODEL F5
A
B
C
9
11/64
10
11/16
7
3/32
Inches
233
272
180
mm
E1: 10-inch long (254mm) tubes are also available.
D
E
F
3 1/2
89
6
152
9 13/32
239
SPECIFICATIONS
NO heavier than # 2 FUEL OIL
0.75 to 1.65 US GPH
105,000 to 231,000 BTU/h
120V 60Hz (+ 10% - 15%)
175 Watts
3250 rpm - 2.2 AMP
12.5 Microfarads
130 to 200 psig
RIELLO 530 SE/C
8Kv 16mA
60º 45º
30º
B
A
MOUNTING FLANGE DIMENSIONS
MODEL F5
Inch
mm
A
B
C
D
1 1/4
32
1/4
6
7/16
11
2 3/16
56
C
D
7 3/32" - 180mm
FUEL:
FIRING RATE:
EFFECTIVE OUTPUT:
VOLTAGE (Single Phase):
ABSORBED ELECTRICAL POWER:
MOTOR (rated):
CAPACITOR:
PUMP PRESSURE:
PRIMARY CONTROL:
IGNITION TRANSFORMER:
3 31/32" - 101mm
5 1/2" - 140mm
7 1/2" - 190mm
8 15/32" - 215mm
C6501000 F3-F5 I-O manual Rev4_3
4
OIL BURNER COMPONENTS IDENTIFICATION
11
10
12
13
9
8
1
7
2
3
6
4
5
STANDARD RIELLO OIL BURNER MODELS 40 F3 & 40 F5 BURNER KEY COMPONENTS
1. 530 SE/C INTEGRATED PRIMARY CONTROL
2. PRIMARY CONTROL SUB-BASE
3. FUEL UNIT (PUMP)
4. PSC MOTOR
5. CAPACITOR
6. AIR ADJUSTMENT AND SHUTTER
7. ELECTRONIC AIR SHUTTER ASSY.
8. WIRE HARNESS FOR AIR SHUTTER
9. COMBUSTION HEAD WITH DRAWER ASSY.
10. SEMI FLANGE 2 PIECES
11. UNIVERSAL MOUNTING FLANGE & GASKET
12. AIR TUBE COVER PLATE
13 PUMP VALVE (COIL)
*PLEASE READ THE MANUAL FOR SPECIFIC INFORMATION ON COMPONENTS
**IF BURNER IS AN OEM BURNER KEY COMPONENTS MAY DIFFER SLIGHTLY
BURNER 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) 8511111 00025
Year of manufacture
BI-week of manufacture
Burner product code
Sequence
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)
C6501000 F3-F5 I-O manual Rev4_3
5
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 8) 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 8).
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.
C6501000 F3-F5 I-O manual Rev4_3
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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.
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.
C6501000 F3-F5 I-O manual Rev4_3
7
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 MAY DAMAGE THE END CONE.
INTERNAL FACTORY WIRING
RIELLO 40 F SERIES OIL BURNERS EQUIPPED
WITH AN ELECTRONIC AIR SHUTTER
INTERNAL FACTORY WIRING
12
11
10
D
A
C
9
B
AUX
11
6
N
L
T
B
D
C
ELECTRIC
AIR SHUTTER
ASSY.
PUMP VALVE
(COIL)
A
M
B
1
2
3
N
4
5
6
L
7
8
AUX
SEE FIELD
WIRING
CAPACITOR
LEGEND:
(A)
(B)
(C)
(D)
(6)
(11)
( )
(AUX)
BROWN
WHITE
BLUE
BLACK
120V SOURCE ACTIVATES SHUTTER OPEN
MOTOR LEAD 120V SOURCE
120V CONTROL LOCK OUT ALARM TERMINAL
CONSTANT 120V AUXILIARY TERMINAL ~ ELECTRONIC AIR SHUTTER
C6501000 F3-F5 I-O manual Rev4_3
8
APPLICATION FIELD WIRING
WIRING DIAGRAM SHOWN BELOW FOR STANDARD RIELLO 530 SE/C PRIMARY CONTROL BOX
INSTALLATION NOTE: ELECTRONIC AIR SHUTTER REQUIRES A CONSTANT 120V POWER
SUPPLY TO THE AUX TERMINAL, FAILURE TO PROVIDE THIS WILL RESULT IN NO BURNER
OPERATION OR AIR SHUTTER WILL NOT CLOSE.
RECOMMENDED FIELD WIRING FOR
TYPICAL APPLICATIONS
120V OPERATED SYSTEMS
L
AUX
N
L
AUX
AIR
SHUTTER
MOTOR.
4
N
24V OPERATED SYSTEMS
AIR
SHUTTER
MOTOR.
4
5
t °
6
T
24V SWITCHING
RELAY
2
2
3
3
6
T
N
1
1
5
L
120VAC 60HZ.
N
L
120VAC 60HZ.
WIRING LEGEND:
PLEASE NOTE: OPERATING LIMIT AND SAFETY LIMIT ARE TWO SEPARATE LIMITS .
(1) MAIN DISCONNECT FUSE
(2) MANUAL SERVICE SWITCH
(3) "SAFETY" LIMIT DEVICE
(4) "OPERATING" LIMIT DEVICE
(5) EARTH GROUND CONNECTION BURNER CHASSIS
(6) BURNER CONTROL REMOTE LOCK OUT ALARM DEVICE - WIRED & SUPPLIED BY OTHERS.
(AUX) AUXILIARY SUB BASE ADD-ON CONNECTOR (AIR SHUTTER)
(T - T)24V THERMOSTAT CONNECTIONS - LOW VOLTAGE OPERATED SYSTEMS
MIN. WIRE SIZE:
INSULATED 18 AWG SOLID OR 16 STRD.
RATED 105° C
PROPER EARTH GROUNDING MEANS REQ.'D
ALL WIRING SHOWN PROVIDED BY OTHERS
WARNING: DO NOT activate burner until proper oil line connections have been made, or
failure of the pump shaft seal may occur.
WARNING: DO NOT activate burner until all safety and operating controls have been
wired in series with the burner, as required by local code authorities and/or as specified by
the appliance manufacturer.
C6501000 F3-F5 I-O manual Rev4_3
9
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.
C6501000 F3-F5 I-O manual Rev4_3
10
ELECTRODE SETTING
IMPORTANT: THIS DIMENSIONS MUST BE OBSERVED AND VERIFIED.
5/32" - 4mm
13/64"
5mm
5/64" to 7/64" or 2 to2.5mm
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
3
specifications shown in this manual.
4
0
2
MODEL F3 NOTE: Zero and four are scale indicators only
From left to right the first line is 3 and the last line 0.
MODEL F5: Same as above, except, scale indicators are 0
and 4.
4
0
1
PUMP CONNECTIONS AND PORT IDENTIFICATION
This burner is shipped with the oil pump set to operate on a single line system. To operate on a two-line system the bypass 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 (7)
for pressure readings. Two PIPE CONNECTORS (4) 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.
12
11
PUMP LEGEND
6
10
1
V
RIELLO
P
2
5
8
9
7
1. PUMP COVER
2. PUMP COVER O-RING
3. BSPP TO NPT ADAPTERS
4. SUPPLY AND RETURN OIL LINES
5. RETURN PORT BY PASS SCREW
6. NOZZLE PORT - PUMP OULET TO NOZZLE
7. PUMP PRESSURE PORT AND BLEEDER PORT
8. PUMP SUPPLY PORT
9. PUMP RETURN PORT
10. PUMP PRESSURE REGULATING SCREW
11. VACUUM PORT
12. PUMP VALVE STEM
4
3
C6501000 F3-F5 I-O manual Rev4_3
11
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
H
3/8” OD
1/2” OD
FT
M
FT
M
FT
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
P
H
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.
NOTE: Do not exceed pipe lengths indicated in
chart.
TWO LINE (LIFT SYSTEM)
H
P
FT
0.0
1.5
3.0
5.0
6.5
9.5
11
2 LINE (LIFT) SYSTEM-PIPE
LENGTHS
H
3/8” OD
1/2” OD
M
FT
M
FT
M
0.0
115
35
330
100
0.5
100
30
330
100
1.0
80
25
330
100
1.5
65
20
295
90
2.0
50
15
230
70
3.0
25
8
100
30
3.5
20
6
65
20
H
NOTE: Do not exceed pipe lengths indicated in
chart.
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 inch size hexagonal key; damage to the by-pass plug may result. When operating on a twoC6501000 F3-F5 I-O manual Rev4_3
12
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 on page 10.
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 start burner.
C
B
II. When bleeding the pump by pressure:
1) Loosen the bleeder valve (A).
2) Disconnect nozzle oil supply line at the pump nozzle port (B).
3) Attach a flexible plastic tube to the pump nozzle, port directing
the oil flow into a bucket.
A
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.
V
RIELLO
P
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.
C6501000 F3-F5 I-O manual Rev4_3
13
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
120v 60Hz.
5
5
4
3
2
2
0
Set the air plate (4) setting according to OEM setup information or by
following the Retrofit settings listed in this manual. To adjust the air
plate (4) to the desired set point indicator (2), loosen the center air
shutter assembly screw (5) and loosen the side air plate screw (3), move
air plate (4) by using the air plate adjust arm. After adjustments are
made please retighten screws (3) & (5).
1
1
The electronic air shutter assembly (1) is operated on a 120v 60Hz.
motor, and the burner motor will not operate until the air shutter is in its
fully open position.
The final position of the air adjustment plate will vary on each
installation. Using proper combustion test instruments to establish the
proper setting of the air gate setting to achieve safe and efficient results
according the appliance information or if not available.
4
3
NOTE: Variations in flue gas, smoke, CO2 and 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 are obtained.
C6501000 F3-F5 I-O manual Rev4_3
14
BURNER ADJUSTMENT TABLES
NON-RETROFIT APPLICATIONS
If this burner is being installed in a packaged unit (i.e. Burner comes with a boiler or 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
ACTUAL FIRING
RATE 5% ±
US GPH
0.50
0.60
0.75
0.80
0.95
NOZZLE
SIZE
GPH
.40 x 60º/80º
.50 x 60º/80º
.60 x 60º/80º
.65 x 60º/80º
.75 x 60º/80º
PUMP
PRESSURE
PSI
BAR
160
11.0
150
10.4
150
10.4
150
10.4
160
11.0
TURBULATOR
SETTING
0.0
0.5
1.5
2.0
3.0
AIR DAMPER
SETTING
2.3
2.7
3.4
3.6
4.3
MODEL F5 BURNER SETUP CHART
ACTUAL FIRING
RATE 5% ±
US GPH
0.75
0.85
1.00
1.10
1.25
1.50
1.65
NOZZLE
SIZE
GPH
.60 x 60/ 80º
.65 x 60/ 80º
.85 x 60/ 80º
1.00 X 60/ 80°
1.10 x 60/ 80º
1.25 x 60/ 80º
1.35 X 60/ 80°
PUMP
PRESSURE
PSI
BAR
145
10
145
10
145
10
145
10
145
10
145
10
145
10
TURBULATOR
SETTING
0.0
0.5
1.0
2.0
2.5
3.0
4.0
AIR DAMPER
SETTING
2.25
2.5
2.75
3.0
3.5
4.25
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).
C6501000 F3-F5 I-O manual Rev4_3
15
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.
Amulet shown in
the flush
mounted position
Head Receeded
1/4 inch max.
NO AMULET
AMULET
flue
gases
flue
gases
tapered combustion
chamber causes
increase in pressure
inside
LOW PRESSURE
LOW PRESSURE
heat
air tube
increase in
pressure down air
tube due to
increase in
combustion
chamber pressure
tapered combustion
chamber causes
increase in pressure
inside
heat
HIGH PRESSURE
air tube
heat
increase in pressure down air
tube due to increase in
combustion chamber
pressure
C6501000 F3-F5 I-O manual Rev4_3
HIGH PRESSURE
heat
AMULET HELPS
PREVENT HOT
GASES FROM
TRAVELLING
DOWN AIR
TUBE
increase in pressure down air
tube due to increase in
combustion chamber
pressure
16
AC
AC
T°
T°
open
open
RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR
CONSTANT UNITERUPTED 120V POWER SUPPLY
CONSTANTAIR
UNITERUPTED
120V POWER SUPPLY
TO ELECTRIC
SHUTTER ASSEMBLY
TO ELECTRIC AIR SHUTTER ASSEMBLY
ELECTRIC AIR SHUTTER MODES
ELECTRIC AIR SHUTTER MODES
BURNER MOTOR STOPS ~ ELECTRIC AIR SHUTTER CLOSES
BURNER MOTOR STOPS ~ ELECTRIC AIR SHUTTER CLOSES
ELECTRIC AIR SHUTTER OPENS ~ ONCE FULLY OPEN SWITCHES POWER TO BURNER MOTOR
ELECTRIC AIR SHUTTER OPENS ~ ONCE FULLY OPEN SWITCHES POWER TO BURNER MOTOR
ELECTRIC AIR SHUTTER CLOSED ~ WAITING FOR CALL FOR HEAT
ELECTRIC AIR SHUTTER CLOSED ~ WAITING FOR CALL FOR HEAT
SHUTTER
NORMAL
OPERATIONAL
SEQUENCE
RIELLO
40 SERIES
OIL BURNER
EQUIPPED
WITH ELECTRIC AIR
SHUTTER NO FLAME OPERATIONAL SEQUENCE
POWER
POWER
STANDY BY
STANDY BY
CALL FOR
CALLHEAT
FOR
HEAT
AIR
AIR
SHUTTER
SHUTTER
MOTOR /
MOTOR
/
PREPURGE
PREPURGE
IGNITION
IGNITION
OIL VALVE
OIL VALVE
FLAME
FLAME
HEAT
SATISFIED
LOCK
OUT
AIR
AIR
SHUTTER
SHUTTER
THERMOSTAT OR LIMIT CONTROL
THERMOSTAT OR LIMIT CONTROL
40 SERIES OIL BURNER MODES
40 SERIES OIL BURNER MODES
17
C6501000 F3-F5 I-O manual Rev4_3
T°
X
closed
closed
T°
AC
CONSTANT UNITERUPTED 120V POWER SUPPLY
TO ELECTRIC AIR SHUTTER ASSEMBLY
ELECTRIC AIR SHUTTER MODES
BURNER MOTOR STOPS ~ ELECTRIC AIR SHUTTER CLOSES
ELECTRIC AIR SHUTTER OPENS ~ ONCE FULLY OPEN SWITCHES POWER TO BURNER MOTOR
ELECTRIC AIR SHUTTER CLOSED ~ WAITING FOR CALL FOR HEAT
RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR
SHUTTER NO FLAME OPERATIONAL SEQUENCE
POWER
STANDY BY
CALL FOR
HEAT
AIR
SHUTTER
MOTOR /
PREPURGE
IGNITION
OIL VALVE
FLAME
LOCK OUT
AIR
SHUTTER
THERMOSTAT OR LIMIT CONTROL
40 SERIES OIL BURNER MODES
18
C6501000 F3-F5 I-O manual Rev4_3
open
X
closed
C6501000 F3-F5 I-O manual Rev4_3
19
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
40
41
42
43
44
45
46
47
48
40
41
42
43
44
45
46
47
48
CODE
F3
3007232
3007233
3006992
3006571
3006993
3005847
3007077
3007568
3007028
3007202
C7010002
3005719
3006925
3007203
3007029
3007156
3007268
3007087
3002278
3006553
3002279
C7001010
3000443
C7001034
3007315
3007316
3002280
•
3948876
3948976
3006968
3006977
3006966
3006965
3008627
3008629
3008633
3008634
3008630
3008631
3005869
3008623
3008626
•
3948877
3948975
3006968
3006977
3006966
3006965
3008790
3008628
3008846
3008635
3008789
3008632
3005869
3008788
3008625
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
RIELLO SPARE PARTS LIST revised November 6, 2002
• Indicates applicable model for each part.
DESCRIPTION
No
CODE
F3 F5
F5
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Burner Back Cover
Burner Back Cover
Pipe Connector Supply
3/8” NPT/Metric Adapter – Male
Pipe Connector Return
¼” NPT/Metric Adapter – Female
Crushable Metal Washer 3/8” ID
Bleeder
O-Ring – Pump Pressure Regulator
Regulator Screw
O-Ring – Pump Cover (3007162)
Pump Screen
Valve Stem
Valve Stem Plate
O-Ring - Valve Stem Upper
O-Ring - Valve Stem Lower
Nozzle Outlet Fitting
Crushable Metal Washer 5/8” ID
Primary Control Sub-Base
Coil U-Bracket and Knurled Nut
Coil
Pump
Pump Drive Key
Motor 120VOLT 60Hz
Air Tube Cover
Air Tube Cover
Photocell
VSBT COMBUSTION HEAD
VSBT Combustion Head 3”
•
VSBT Combustion Head 3”
•
Turbulator Disc
•
Turbulator Disc
•
•
Electrode Support
•
•
Nozzle Adapter
•
Nozzle Oil Tube
•
Nozzle Oil Tube
•
Regulator Assembly
•
Regulator Assembly
•
Electrode Assembly
•
Electrode Assembly
•
•
Electrode Porcelain
•
Air Tube only
•
Air Tube only
8 7/8" COMBUSTION HEAD
•
Combustion Head 8 7/8"
•
Combustion Head 8 7/8"
•
Turbulator Disc
•
Turbulator Disc
•
•
Electrode Support
•
•
Nozzle Adapter
•
Nozzle Oil Tube
•
Nozzle Oil Tube
•
Regulator Assembly
•
Regulator Assembly
•
Electrode Assembly
•
Electrode Assembly
•
•
Electrode Porcelain
•
Air Tube only
•
C6501000 F3-F5 I-O manual Rev4_3
Air Tube only
26
27
28
29
C7001029
3005854
3005855
3005856
C7001081
C7001082
•
•
•
•
•
3007207
3007208
3005844
C7001031
C6950050
3007320
3007221
3007222
•
49
C7001033
•
•
50
C7001085
•
•
Type L 24 volt switching relay
51
52
2623141
3000932
•
•
•
•
Capillary port plug
Adjustable Steel Flange
3948873
3948973
3006968
3006977
3006966
3006965
3006969
3006973
3006324
3006323
3006330
3006329
3005869
3007592
3007594
•
3948874
3948974
3006968
3006977
3006966
3006965
3006970
3006974
3005867
3005878
3005870
3005880
3005869
3007593
•
30
34
35
36
37
38
40
41
42
43
44
45
46
47
48
40
41
42
43
44
45
46
47
48
3007595
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
DESCRIPTION
•
•
•
•
•
•
Primary Control
Semi Flange (2 Required)
Universal Mounting Flange
Mounting Gasket
F3 replacement air damper kit
F5 replacement air damper kit
Air Intake Housing
Air Intake Housing
Capacitor 12.5µF
Fan
Acoustic Liner
Acoustic Liner
Chassis Front Plate
Chassis Front Plate
OPTIONAL
Amulet – Cerafelt Sleeve Kit
SHORT COMBUSTION HEAD
Short Combustion Head 6” (271T1)
•
Short Combustion Head 6” (271T1)
Turbulator Disc
•
Turbulator Disc
•
Electrode Support
•
Nozzle Adapter
Nozzle Oil Tube – Short
•
Nozzle Oil Tube – Short
Regulator Assembly – Short
•
Regulator Assembly – Short
Electrode Assembly – Short
•
Electrode Assembly – Short
•
Electrode Porcelain
Air Tube only
•
Air Tube only
LONG COMBUSTION HEAD
Long Combustion Head 10” (271T2)
•
Long Combustion Head 10” (271T2)
Turbulator Disc
•
Turbulator Disc
•
Electrode Support
•
Nozzle Adapter
Nozzle Oil Tube – Long
•
Nozzle Oil Tube – Long
Regulator Assembly – Long
•
Regulator Assembly – Long
Electrode Assembly – Long
•
Electrode Assembly – Long
•
Electrode Porcelain
Air Tube only
•
Air Tube only
20
35 Pond Park Rd.
Hingham, MA 02043
Phone: 781-749-8292
Toll Free: 800-992-7637
Fax: 781-740-2069
2165 Meadowpine Blvd.
Mississauga, On L5H R2
Phone: 905-542-0303
Toll Free: 800-387-3898
Fax: 905-542-1525
BURNER START- UP FORM *
Burner S/N. or
Model:
Appliance:
Installer name:
Installation
date:
Company:
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:
Turbulator
setting:
Air Setting:
Draft
breech:
Draft Over fire:
CO2:
Air Setting:
Single
Line:
Draft
breech:
Draft Over fire:
CO:
Smoke density:
Head Setting:
O2:
(Bacharach)
Two
Lines:
CO2:
CO:
O2:
Manifold pressure:
Ionization Reading
(µAd.c.):
Input
BTU/Hr:
This form was designed and provided i n 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
C6501000 F3-F5 I-O manual Rev4_3
21
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: techservices@riellocanada.com
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/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.
C6501000 F3-F5 I-O manual Rev4_3
22
C6501000 F3-F5 I-O manual Rev4_3
23
35 Pond Park Road
Hingham, MA 02043
Phone 781-749-8292
Toll Free 800-992-7637
Fax 781-740-2069
www.riellousa.com
2165 Meadowpine Blvd
Mississauga, ON L5N 6H6
Phone 905-542-0303
Toll Free 800-387-3898
Fax 905-542-1525
www.riellocanada.com
Technical Support Hotline
1-800-4-RIELLO
1-800-474-3556
C6501000 F3-F5 I-O manual Rev4_3
24