Installation & Operating Manual

Single stage operation oil burners

RETROFIT APPLICATIONS ONLY

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.
- The following pages contain information, descriptions and diagrams for the proper installation
and wiring of the burner. Please read carefully before attempting final installation.
- This manual is to remain with the final installation designation. It is the installer’s responsibility to en-
sure that the burner installation and operation instructions mentioned in this manual are followed and
operated within local code authority limits.

RIELLO 40
CODE MODEL TYPE

C8512519 800057000-Brn-PO Rie F5 1.00GPH Vnt-C

C8512520 800058000-Brn-PO Rie F5 1.20GPH Vnt-C
C8512521 800059000-Brn-PO Rie F5 1.40GPH Vnt-C

C6501071(0)
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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 suffi-
cient 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 con-
nected 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 EXTINGUISHER
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.

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TABLE OF CONTENTS

PACKAGE CONTENTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SERIAL NUMBER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mounting flange dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INITIAL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OIL BURNER COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Burner components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ASSEMBLY OF AIR TUBE TO BURNER CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MOUNTING BURNER TO BOILER OR FURNACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Method 1-Universal Mounting Flange. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Method 2-Semi-flange Collar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Method 3-Pedestal Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AMULET INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INTERNAL FACTORY WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
APPLICATION FIELD WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
NOZZLE PLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSERTION / REMOVAL OF DRAWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ELECTRODE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TURBULATOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OIL LINE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 12
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PUMP PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SETTING THE AIR ADJUSTMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BURNER ADJUSTMENT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BURNER START-UP CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EXPLODED SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPARE PARTS LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - 16

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PACKAGE CONTENTS LIST

Your Riello 40 burner should include the following parts. Please check to make sure all parts are present before begin-
ning the installation.

Quantity Description Code

1 Burner with combustion head mounted C8512519 - C8512520 - C8512521
1 Mounting gasket C6880016
1 Parts bag 2569525
1 Parts bag 2569526
1 Installation manual C6501071
Separate carton - OEM burners shipped with combustion head mounted
1

Parts bag 2569525 Parts bag 2569526

Quantity Description Quantity Description
2 Semi-flange bolts (long)
1 By-pass plug
2 Semi-flanges
1 Female ¼” NPT adapter
2 Mounting flange bolts (short)
1 Male 3/8” NPT adapter
4 Nuts
1 2.5 mm Allen key
2 Chrome nuts
1 Oil pump connector (supply)
1 Oil pump connector (return)

SERIAL NUMBER IDENTIFICATION

Your Riello burner may have been manufactured in more than one location and therefore there are two possible serial
number identification.
(06) (01) (12345)
The Riello 9 character serial number, example,
06 01 12345, is identified as follows:
06 = Last two digits of the year of manufacture;
01 = Week of manufacture; Year of BI-week of
12345 = Increment of 1 for each burner produced – specific manufacture manufacture Increment
to product code – reset to zero each January 1st.

(06) (A) (8511111) (00025)

The Riello 15 character serial number, example,
06 A 8511111 00025, is identified as follows:
06 = Last two digits of the year of manu-
facture; Year of BI-week of BI-week of
A = BI-week of manufacture; manufacture manufacture manufacture Increment
8511111 = Burner product code;
00025 = Increment of 1 for each burner pro-
duced – specific to product code –
reset to zero each January 1st.

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TECHNICAL DATA B
SPECIFICATIONS
Fuel No heavier than # 2 fuel oil
F3 Firing rate - Effective Output 0.50 to 0.95 US GPH - 70,000 to 133,000 BTU/h
F5 Firing rate - Effective Output 0.75 to 1.65 US GPH - 105,000 to 231,000 BTU/h

A
Voltage (single phase) 120V 60Hz (+ 10% - 15%)
F3 Absorbed electrical power 155 Watts
F5 Absorbed electrical power 175 Watts
Motor (rated) 3250 rpm Run Current 2.2 AMP
Capacitor 12.5 Microfarads
Pump pressure 130 to 200 psig
E F
Primary control RIELLO 530 SE/C E1
Ignition transformer 8kV 16mA

BURNER DIMENSIONS

D
Model A B C D E F

C
Inches 8 15/32 9 59/64 6 15/32 3 1/2 6 8 29/32
F3
mm 215 252 164 89 152 226
Inches 9 11/64 10 11/16 7 3/32 3 1/2 6 9 13/32
F5
mm 233 272 180 89 152 239 D7352

E1: 10-inch long (254mm) tubes are also available. °

60 45°
30°

BURNER COMPONENTS IDENTIFICATION

7 3/32” - 180 mm
1 7
3 31/32”
101 mm

3
5 1/2”-140mm
6
7 1/2” - 190 mm
4
8 15/32” - 215 mm
D7351
5

8 9 BURNER COMPONENTS
1 Lockout indicator lamp and reset button
2 Primary control
3 Primary control sub-base
4 Pump pressure regulator
5 Motor
6 Air adjustment and shutter
10 12 7 Electronic air shutter assembly
8 Combustion head
9 Semi flange 2 pieces
10 Mounting flange with gasket
11 13 11 Supply fuel line port
12 Pump valve (coil)
15 14 13 Vacuum gauge port
14 Pressure gauge and bleeder port
D7304 15 Return fuel line port

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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.
C) Remove drawer assembly from air tube, insert nozzle and set Turbulator adjustment for specific input required, then
set aside.
D) Mount air tube to burner chassis.

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 in-
stallation.
A) Remove the AIR TUBE and BURNER
CHASSIS from their respective cartons.
B) Remove the DRAWER ASSEMBLY (1) S7462
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) re-
moved. Replace the BOLTS and fingers tighten only. Re-install DRAWER ASSEMBLY into AIR TUBE. Tighten
SCREW (2) securely.
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.

METHOD 1 – UNIVERSAL MOUNTING FLANGE

DRY BASE A
BOILER

D6013

A
COMBUSTION
CHAMBER

B
S7461

D6014

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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/fur-
nace 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 us-
ing 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.

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AMULET INSTALLATION INSTRUCTIONS Amulet shown in the

(Required on some models) flush mounted position

The amulets provided have been selected by Riello to protect the

combustion tube from hot exhaust gases and flame. This protec-
tion 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. Head receeded
Do not exert undue pressure when pushing the amulet over the 1/4 inch max.
combustion tube. D7285
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.

NO AMULET AMULET

FLUE GASES FLUE GASES

Tapered combustion Tapered combustion

chamber causes increase chamber causes increase
in pressure inside in pressure inside

LOW PRESSURE LOW PRESSURE

HEAT HEAT
AIR TUBE HIGH PRESSURE AIR TUBE HIGH PRESSURE
HEAT HEAT
Increase in pressure Increase in pressure down Amulet helps prevent Increase in pressure down
down air tube due air tube due to increase not gases from air tube due to increase
to increase in in combustion chamber travelling down in combustion chamber
combustion chamber pressure air tube pressure
pressure
S7941

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INTERNAL FACTORY WIRING

RIELLO 40 F3 - F5 SERIES OIL BURNERS EQUIPPED

WITH AN ELECTRONIC AIR SHUTTER
INTERNAL FACTORY WIRING

PUMP VALVE
(COIL)

ELECTRONIC AIR
SHUTTER ASSY.
MOTOR

D7328
CAPACITOR

Key to lay-out:
A - Brown 6 - 120V source activates shutter open
B - White 11 - motor lead 120V source
C - Blue - 120V control lock out alarm terminal
D - Black AUX - costant 120V auxiliary terminal - electronic air shutter

ATTENTION !!
³ Do not swap neutral and phase over, follow the diagram shown carefully and carry out a good earth
connection.
³ Minimum wire size AWG 18.
³ All wiring must be done in accordance with existing codes, both national and local.

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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 SHUT-
TER WILL NOT CLOSE.
AIR SHUTTER AIR SHUTTER
MOTOR MOTOR

SWITCHING
RELAY
24V
PLEASE NOTE: OPERATING LIMIT AND SAFETY LIMIT ARE TWO SEPARATE LIMITS.
Key to lay-out:
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 bub base add-on connector (air shutter)
T - T - 24V thermostat connections - low voltage operated system

MIN. WIRE SIZE:

INSULATED 18 AWG SOLID OR 16 STRD. RATED 105° C
PROPER EARTH GROUNDING MEANS REQUIRED ALL WIRING SHOWN PROVIDED BY OTHER.

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.

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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 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 AS-
SEMBLY by loosening the SCREW (1).
C) Insert the proper NOZZLE into the NOZZLE ADAPTER and
tighten securely (Do not over tighten).
S7459
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 un-
plug CONTROL BOX (1) by care-
fully pulling it back and then up.
C) Remove the AIR TUBE COVER
PLATE (5) by loosening the re-
t a i n i n g S C R E W ( 4 ) ( Tw o
SCREWS – Model F5).
D) Loosen SCREW (2), and then
slide the complete drawer assem-
bly out of the combustion head as
shown.
E) To insert drawer assembly, re-
verse the procedure in items A to
D above. S7460

ELECTRODE SETTING 5/32” or 4 mm

13/64”
5 mm
IMPORTANT:
These dimensions must be observed and verified.

D6003
5/32” to 13/64” or 4 to 5 mm

TURBULATOR SETTING 3
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. 2
B) Retighten the RETAINING NUT (1).
NOTE: OEM specifications take priority over retrofit specifications
shown in this manual. 1
MODEL F3: Zero and three are scale indicators only. From left to D5997

right the first line is 3 and the last line 0.

MODEL F5: Same as above, except scale indicators are 0 and 4.

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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 (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
8

5 7

4 4

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.
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.

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
P

3.0 1.0 65 20 130 40 ATTENTION:

H

do not exceed
5.0 1.5 130 40 260 80 pipe lengths
6.5 2.0 195 60 325 100 indicated in chart!

D6009

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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 inch 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 sys-
tem. Any obstructions in the return line will cause failure of the pump shaft seal.

H
2 LINE (LIFT) SYSTEM-PIPE LENGTHS
H 3/8” OD 1/2” OD
FT M FT M FT M

P
0.0 0.0 115 35 330 100
ATTENTION:
1.5 0.5 100 30 330 100 do not exceed
3.0 1.0 80 25 330 100 pipe lengths
5.0 1.5 65 20 295 90 indicated in chart!
6.5 2.0 50 15 230 70
9.5 3.0 25 8 100 30 D6008

11 3.5 20 6 65 20

H
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.
- The height ‘P’ in Pipe Length Charts should not exceed 13 feet (4 m).
- 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). B 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 re-
moved 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 A
starting, remove the air tube cover and shine a light source on the
photocell, allowing it to see false light. D7284

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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 haz-
ardous situation upon burner startup.

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 suffi-
ciently 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 1

The electronic air shutter assembly (1) is operated on a
120V 60Hz. motor, and the burner motor will not operate un-
til the air shutter is in its fully open position.
Set the air plate (4) setting according to OEM setup informa-
tion or by following the Retrofit settings listed in this manual. 2 5
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 us-
ing the air plate adjust arm. After adjustments are made
please retighten screws (3) & (5).
The final position of the air adjustment plate will vary on 3 4
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 D7305
information or if not available.

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.

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BURNER ADJUSTMENT TABLE

NON-RETROFIT APPLICATIONS
If this burner is being installed in a packaged unit (i.e. Burner comes with a boiler or furnace), follow the instal-
lation and set-up instructions supplied with the heating appliance, as settings will differ from those shown in
this manual.
RIELLO BURNER SET UP SHEET

Weil McLain Part No. 8000-5700 8000-5800 8000-5900

Riello Part No. C8512519 C8512520 C8512521
Riello 40 F5 Factory F5 Factory F5 Factory
F5
Burner Model Series preset *1 preset *1 preset *1
Boiler UO3 UO3 UO4 UO5
Input GPH 0,8 1,0 1,2 1,4
Nozzle Delavan .65 X 70°B .85 X 60°B 1.00 X 70°B 1.10 X 70°B
Pump Pressure PSI 150 145 145 160
Turbolator Setting 0 1 3 4
Air Gate Setting 2.75 2.8 2.9 2.9
Air tube length inches 8 8 8 8

Ait tube insertion inches 4 1/4" 4 1/4" 4 1/4" 4 1/4"

*1 Nozzle pre-installed at factory.

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 appropri-
ate installation codes (e.g. CSA B139 or NFPA #31).

BURNER START-UP CYCLE

Normal Lock-out, due to light-failure
Thermostat
Motor
Ignition transformer
Valve
Flame
Lock-out lamp
D5229

~ 12s ~ 12s ~ 5s

3223
12
EXPLODED SPARE PARTS LIST

35
{
13
SPARE PARTS LIST

No. CODE F3 F5 DESCRIPTION No. CODE F5 DESCRIPTION

OPTIONAL
1 3007232 • BURNER BACK COVER 60 C7001085 • • TYPE L 24V SWITCHING RELAY
1 C8111227 • BURNER BACK COVER 61 C7001033 • • AMULET - CERAFELT SLEEVE KIT
2 3006992 • • PIPE CONNECTOR - SUPPLY
3 3006571 • • 3/8” NPT/METRIC ADAPTER - MALE
4 3006993 • • PIPE CONNECTOR - RETURN 3007943 • • CAPILLARY PORT PLUG
5 3005847 • • 1/4” NPT/ METRIC ADAPTER - FEMALE
6 3007077 • • CRUSHABLE METAL WASHER
7 3007568 • • BLEEDER
8 3007028 • • O-RING - PUMP PRESSURE REGULATOR
9 3007202 • • REGULATOR SCREW
10 3007162 C7010002 • • O-RING - PUMP COVER
11 3005719 • • PUMP SCREEN
12 3006925 • • VALVE STEM
13 3007203 • • VALVE STEM PLATE
14 3007029 • • O-RING - VALVE STEM UPPER
15 3007156 • • O-RING - VALVE STEM LOWER
16 3007268 • • NOZZLE OUTLET FITTING
17 3007087 • • CRUSHABLE METAL WASHER 5/8” ID
18 3001157 C7001029 • • PRIMARY CONTROL 530SE/C
19 3002278 • • PRIMARY CONTROL SUB BASE
20 3006553 • • COIL U-BRACKET AND KNURLED NUT
21 3002279 • • COIL
22 3007802 • • PUMP
23 3000443 • • PUMP DRIVE KEY
24 3005843 • • MOTOR
25 3007315 • AIR TUBE COVER
25 3007316 • AIR TUBE COVER
26 3002280 • • PHOTOCELL
27 3005854 • • SEMI FLANGE (2 REQUIRED)
29 3020248 • • MOUNTING GASKET
30 3005708 • • FAN
31 3005844 • • CAPACITOR 12.5 µF
32 3002864 C6950050 • ACOUSTIC LINER
32 3007320 • ACOUSTIC LINER
33 3007204 • • MANUAL AIR SHUTTER
34 3020249 • • ELECTRONIC AIR SHUTTER
35 C7001081 • F3 REPLACEMENT AIR DAMPER KIT
35 C7001082 • F5 REPLACEMENT AIR DAMPER KIT

14
SPARE PARTS LIST

No. CODE F5 DESCRIPTION

40 3948876 • VSBT COMBUSTION HEAD 3”

40 C7001331 • F5 SBT WELDED 4.25" COMPLETE
41 3006968 • TURBULATOR DISC
41 3006977 • TURBULATOR DISC
42 3006966 • • ELECTRODE SUPPORT
43 3006965 • • NOZZLE ADAPTER
44 3008627 • NOZZLE OIL TUBE
44 3008629 • NOZZLE OIL TUBE
45 3008633 • REGULATOR ASSEMBLY
45 3008634 • REGULATOR ASSEMBLY
46 3008630 • ELECTRODE ASSEMBLY
46 3008631 • ELECTRODE ASSEMBLY
47 3005869 • • ELECTRODE PORCELAIN
48 3008623 • AIR TUBE
48 3008626 C7001335 • F5 SBT WELDED 4.25" TUBE ONLY

15
 GB

35 Pond Park Rd. 2165 Meadowpine Blvd.

Hingham, MA 02043 Mississauga,On L5H 3R2
Phone: 781-749-8292 Phone: 905-542-0303
Toll Free: 800-992-7637 Toll Free: 800-387-3898
Fax: 781-740-2069 Fax: 905-542-1525

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)

Nozzle info: Pump pressure:

Air setting: Turbolator setting:

Draft overfire: Draft breech:

CO2: CO: O2: Smoke density: (Bacharach)

Single line: Two lines:

* This form was designed and provided in the installation manual for reference and also for providing tech-
nical information which can be faxed or mailed to our technical hot-line coordinator when technical assis-
tance 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

3223
 35 Pond Park Road 2165 Meadowpine Blvd
Hingham, MA 02043 Mississauga, ON L5N 6H6
Phone 781-749-8292 Phone 905-542-0303
Toll Free 800-992-7637 Toll Free 800-387-3898
Fax 781-740-2069 Fax 905-542-1525

www.riellousa.com www.riellocanada.com

Technical Support Hotline

1-800-4-RIELLO
1-800-474-3556