Riello 40BF Installation instructions

Installation & Operating Manual

C6505027 - 20015900 (3) - 07/2014

Single stage operation oil burners

CODE MODEL TYPE

3729010 BF3 290T

3729110 BF5 291T

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.

This burner is not equipped for 2 line operation.

For 2 line operation order: part # C7001025 for BF3, C7001026 for BF5.

WARNING

20015900

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 room is enclosed. It may be necessary to create a window to permit sufficient air to

enter the boiler 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.

The burner settings used in this manual were obtained under laboratory conditions and may vary

from those obtained in the actual installation of the burner. Combustion results must be verified

using proper combustion test equipment. Riello will not be responsible for the improper

installation or set-up of the appliance.

ATTENTION

20015900

TABLE OF CONTENTS

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

SERIAL NUMBER IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TECHNICAL DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Burner and mounting flange dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Burner components identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MOUNTING THE BURNER TO BOILER OR FURNACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

APPLICATION FIELD WIRING - RIELLO 530 SE/C PRIMARY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

APPLICATION FIELD WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

APPLICATION FIELD WIRING - RIELLO 530 SE/C 24 VPRIMARY CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

INSTALLATION/ REMOVAL OF DRAWER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ELECTRODE SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

NOZZLE PLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

TURBULATOR SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

OIL LINE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

PUMP PURGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Single line (Gravity feed system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Two line (Lift system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

SETTING THE AIR ADJUSTMENT PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

COMBUSTION CHAMBER PRESSURE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

BURNER START-UP CYCLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

BURNER ADJUSTMENT TABLES - BURNER SETUP CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

A TYPICAL LAYOUT FOR BF BURNER INTAKE AIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

TROUBLE SHOOTING CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

EXPLODED SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

BURNER START-UP LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

20015900

PACKAGE CONTENTS LIST

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

ginning the installation.

SERIAL NUMBER IDENTIFICATION

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;

A= BI-week of manufacture;

8511111 = Burner product code;

00025 = Increment of 1 for each burner pro-

duced – specific to product code –

reset to zero each January 1st.

Quantity Description Code

1 Burner chassis with cover 3729010 - 3729110

1 Gasket 2567340

1 Nut 2621854

1 Connector 2623842

1 Installation manual

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

Year of

manufacture Burner

product code Increment

BI-week of

manufacture

20015900 2

TECHNICAL DATA

SPECIFICATIONS

BURNER AND MOUNTING FLANGE DIMENSIONS

BURNER COMPONENTS IDENTIFICATION

Fuel No. 2 Fuel Oil

BF3 Firing rate - Effective Output 0.50 to 0.95 US GPH - 70,000 to 133,000 BTU/h

BF5 Firing rate - Effective Output 0.75 to 1.65 US GPH - 105,000 to 231,000 BTU/h

Voltage (single phase) 120V 60Hz (+ 10% - 15%)

BF3 Absorbed electrical power 192 Watts

BF5 Absorbed electrical power 204 Watts

Motor (rated) 3250 rpm Run Current 2.2 AMP

Capacitor 12.5 Microfarads 260V

Pump pressure 100 to 200 PSI

Primary control RIELLO 530 SE/C - RIELLO 530 SE/C 24 V

Ignition transformer 8kV 16mA

Model ABCDE*E1F

BF3 Inches 9 13/16 11 1/4 7 1/2 3 1/2 4 1/4 6 8 1/4

mm 249 286 193 89 108 152 210

BF5 Inches 9 13/16 11 1/2 7 1/2 3 1/2 4 1/4 8 7/8 8 3/4

mm 249 292 193 89 108 225 222

5 9/16”-141mm

7 9/16” - 192 mm

8 1/2” - 216 mm

3 9/16”

90 mm

60°

45°

30°

BURN-

ER COMPONENTS

1Lockout indicator lamp and reset button

2Primary control

3Primary control sub-base

4Pump pressure regulator

5Post purge timer (option)

6Air adjustment

7Capacitor

8Combustion head

9Mounting gasket

10 Universal mounting flange

11 Turbolator adjustment screw

12 Coil

13 Bleeder and pressure gauge port

14 Return fuel line port

15 Inlet fuel line port

16 Pump

17 24 V thermostat connections

D7516

D7515

*E1

D7517

8 9 10

1314

*E1: 6” (152 mm) 8 7/8” (225mm) & 10” (254 mm) tubes are also available.

20015900

MOUNTING THE BURNER TO THE BOILER OR FURNACE

There are two possible methods to mount the burner, depending on the individual application. These are:

1) Universal flange bolted to Boiler/Furnace unit.

2) 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) Slide the UNIVERSAL MOUNTING FLANGE (1) over

the end cone assembly with the flat flange surface to-

wards the heating unit.

B) Secure the UNIVERSAL MOUNTING FLANGE to the

AIR TUBE by tightening the ALLEN BOLT (2). Be sure

that the MOUNTING FLANGE is properly positioned. The

outer edge of the END CONE will be at least 1/4” (6.5

mm) back from the inside wall of the refractory chamber

or inside wall of the combustion chamber (see dimension

B above). The measured length (A) is to include the

MOUNTING GASKET (3) and FLANGE.

C) For dry based appliances it is suggested that an amu-

let or cera-felt sleeve be used on the end cone to help re-

duce the risk of end cone burn-off. This amulet also

provides an additional benefit of sealing the chamber air

tube hole when this hole is larger then our air tube diam-

eter. Please refer to amulet instructions in regards to in-

stalling amulet to the burners air tube end cone.

D) The burner can now be attached to the heating unit by

inserting the AIR TUBE through the BURNER ACCESS

HOLE (5) and into the appliance, making sure the

MOUNTING FLANGE lines up with the appliance studs

(6). Secure the burner in place using nuts (4).

A visual verification of the air tube insertion into the com-

bustion chamber of the heating unit is suggested. Dimen-

sion “B” should be at least 1/4 inch (see drawing).

METHOD 2 – PEDESTAL MOUNT

Secure the MOUNTING FLANGE to MOUNTING PED-

ESTAL using the hardware provided with the pedestal.

Secure burner to MOUNTING FLANGE as in METHOD

NOTE: It is suggested that the pedestal be anchored in

position on the floor by installing brackets over the ped-

estal tube and securing brackets to the floor.

WHEN THE COMBUSTION CHAM-

BER IS LINED WITH A REFRACTORY

MATERIAL, IT IS IMPERATIVE THAT

THE END CONE NOT PROTRUDE

INTO THE CHAMBER AREA, AS EXCESSIVE

HEAT AT BURNER END CONE DURING OPER-

ATION OR SHUTDOWN WILL DAMAGE THE

END CONE. IF HIGH END CONE TEMPERA-

TURES ARE A CONCERN USING A CERA-FELT

SLEEVE OR, AMULET OVER THE END CONE

COULD HELP REDUCE THE RISK OF BURN-

OFF THE END CONE.

D9646

125

CERA-FELT

SLEEVE OR

AMULET

SHOWN

D9647

D9648

WET BASED

CHAMBER

APPLICATIONS

DRY BASED

CHAMBER

APPLICATIONS

WARNING

20015900 4

ELECTRICAL CONNECTIONS

It is advisable to leave the control box off the sub-base while

completing the electrical connections to the burner.

1) Electrical connector

2) Earth ground conductor terminal

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 models Riello or

Honeywell R8038A 24v relays or a LOW VOLTAGE

THERMOSTAT INPUT (T-T).

Following the wiring diagram on the next page, make electrical

connections to burner. All wiring must be done in accordance

with existing electrical codes, both National and Local.

Do not activate burner until proper oil line connections have been made, or failure of the pump shaft seal may

occur.

APPLICATION FIELD WIRING - RIELLO 530 SE/C PRIMARY CONTROL

S7954

WARNING

REMOTE SENSING OF

SAFETY LOCKOUT

The SAFETY SWITCH in

the 530 SE/C CONTROL

BOX is equipped with a con-

tact allowing remote sens-

ing of burner lockout. The

electrical connection is

made at terminal 4 (•) on

the SUB-BASE.

Should lockout occur the

530 SE/C CONTROL BOX

will supply a power source

of 120Vac to the connection

terminal.

The maximum allowable

current draw on this termi-

nal (4) is 1 Amp.

If a neutral or

ground lead is

attached to this

terminal, the

CONTROL BOX on the

burner will be damaged

should lockout occur.

WARNING

EARTH GROUND (Green)

NEUTRAL (White)

HOT LINE (Black)

EARTH GROUND (Green)

NEUTRAL (White)

HOT LINE (Black)

TRANSFORMER

Blue

White

Black

Brown

White

Blue

Brown

Black

CAPACITOR

VALVE

MOTOR

COIL

234567891

NLNL

FACTORY

WIRED

SUB-BASE

T24V

120V

LINE SAFETY

SWITCH

OPERATING

LIMIT SWITCH

SAFETY

LIMIT SWITCH

FUSE 15A

120V

Black

White

LINE SAFETY

SWITCH

OPERATING

LIMIT SWITCH

SAFETY

LIMIT SWITCH

FUSE 15A

SWITCHING RELAY

D5995

DIRECT LINE LOW VOLTAGE

VOLTAGE

20015900

APPLICATION FIELD WIRING

Capacitor

GREEN

BLUE

BLACK

WHITE

BLUE

BROWN

AL 1009-1

Burner Fan-Off

Timer

YELLOW

BLUE

RED

GREY

WHITE

BLACK

RED

WGR B

WHITE

RED

BROWN

Ground

FACTORY WIRED

SUB BASE

LIMIT

Switches

SAFETY

Switches

Fuse 15A

L1L2 Earth

Ground

WHITE

GREEN

RED

BLACK

Motor

FIELD

WIRING

Oil Valve Control Box

530 SE/C

All the installation, maintenance and disassembly operations MUST be carried out with the electric-

ity supply disconnected.

The installation of the burner must be carried out by qualified personnel, as indicated in this manual

and in compliance with the standards and regulations of the laws in force.

DANGER

WARNING

D7518

20015900 6

APPLICATION FIELD WIRING - RIELLO 530 SE/C 24V PRIMARY CONTROL

REMOTE SENSING OF SAFETY LOCKOUT

The SAFETY SWITCH in the 530 SE/C 24V 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 530 SE/C 24V 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.

If a neutral or ground lead is attached to this terminal, the CONTROL BOX on the burner will be

damaged should lockout occur.

123456789

120 V

D8794

FACTORY

WIRED

SUB-BASE

EARTH GROUND (GREEN)

NEUTRAL (WHITE)

HOT LINE (BLACK)

24V OPERATING

LINE SAFETY

SWITCH

OPERATING

LIMIT SWITCH

SAFETY

LIMIT SWITCH

FUSE 15A

NL NL

EARTH GROUND (GREEN)

NEUTRAL (WHITE)

HOT LINE (BLACK)

FUSE 15A

LINE SAFETY

SWITCH

SAFETY

LIMIT SWITCH LIMIT SWITCH

ON LEFT SIDE OF

THE CONTROL BOX

ON LEFT SIDE OF

THE CONTROL BOX

Blue

White

Black

Brown

White

Blue

Brown

Black

CAPACITOR

MOTOR

COIL

Black

White

DIRECT LINE LOW VOLTAGE

VOLTAGE

WARNING

20015900

INSTALLATION/REMOVAL OF DRAWER ASSEMBLY

Removal:

A) Loosen off oil delivery tube nut from pump.

B) Loosen SCREW (3), and then unplug CON-

TROL 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 BF5).

D) Loosen SCREW (2), and then slide the

complete drawer assembly out of the com-

bustion head as shown.

E) To insert drawer assembly, reverse the pro-

cedure in items A to D above.

ELECTRODE SETTING

IMPORTANT:

These dimensions must be observed and verified.

NOZZLE PLACEMENT

- Remove the NOZZLE ADAPTER (2) from the DRAWER

ASSEMBLY by loosening the SCREW (1).

- Insert the properNOZZLE into the NOZZLEADAPTER and

tighten securely (Do not over tighten).

- Replace adapter, with nozzle installed, into drawer assem-

bly and secure with screw (1).

IMPORTANT:

The nozzle and the pump pressure must be in accordance with the burner setup chart at page 12.

TURBULATOR SETTING

A) Loosen NUT (1), and then turn SCREW (2) until the

INDEX MARKER (3) is aligned with the correct in-

dex number as per the burner setup chart at page 9.

B) Retighten the RETAINING NUT (1).

MODEL BF3: Zero and three are scale indicators only.

From left to right the first line is 3 and the last line 0.

MODEL BF5: Same as above, except scale indicators

are 0 and 4.

E9327

5/32” or 4 mm

5/32” to 13/64” or 4 to 5 mm

13/64”

5 mm

D6003

S7459

D7520

This manual suits for next models

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