Riello R35 Series User manual

OIL BURNER

R35 SERIES

INSTALLATION MANUAL

If this burner is being installed in a packaged unit (ie. Burner comes with a boiler or furnace), follow

the installation and set-up instructions supplied with the heating unit, as settings may differ from

those in this manual.

C6501016 29-Mar-11 STANDARD R35 MANUAL REV 1-3

.DOC

TABLE OF CONTENTS

PAGE

BURNER MODEL IDENTIFICATION…………………………………………..

TECHNICAL DATA:

DIMENSIONS………………………………………….. 3

SPECIFICATIONS……………………………………...

……..

COMPONENT IDENTIFICATION……………………………………………… 4

MOUNTING THE BURNER…………………………………………………….. 5

ELECTRICAL CONNECTIONS………………………………………………… 6

FIELD WIRING…………………………………………………………………... 7

REMOTE SENSING OF SAFETY LOCKOUT SWITCH………………………. 8

REMOVAL OF DRAWER ASSEMBLY………………………………………... 9

INSTALLING THE NOZZLE…………………………………………………… 9

ELECTRODE ADJUSTMENT………………………………………………….. 9

OIL LINE CONNECTIONS: BY-PASS PLUG INSTALLATION…………… 10

SINGLE LINE SYSTEM………………………. 10

TWO LINE SYSTEM………………………….. 11

PUMP PURGE……………………………………………………………………. 12

WORKING FIELD……………………………………………………………….. 13

BURNER SET-UP: TURBULATOR SETTING……………………………… 13

AIR DAMPER SETTING……………………………….. 13

SET-UP CHARTS……………………………………….. 14

RECOMMENDED NOZZLES…………………………...

AMULET INSTALLATION INSTRUCTIONS……..…………………………... 15

SPARE PARTS EXPLODED VIEW……………………………………………...

SPARE PARTS LIST……………………………………………………………...

INSTALLATION PRECAUTION:

…………………………………………….

CARTON CONTENTS

Your RIELLO 35 burner carton includes the following parts. Please check to make sure

all parts are present before beginning the installation.

1 – Burner

1 – Mounting Flange

1 – Mounting Gasket

1 – By-pass Plug (attached to burner)

SERVICE TOOLS REQUIRED

1 – No 1 Philips Screwdriver

1 - No. 2 Philips Screwdriver

1 – No. 2 Slotted Screwdriver

1 – 1 inch Adjustable Wrench

4 – Allen Keys: 2.5 mm – Pump By-pass Plug

1/8 inch – Pump Pressure Regulator

5/32 inch – Pump – Cover & Mounting Bolts, Blower Fan

7/32 inch – Adjustable Flange Bolt

BURNER MODEL IDENTIFICATION

HOW TO READ BURNER MODEL IDENTIFICATION

EXAMPLE

R35 . 3 . 03 . R . 0

R35.3

MODEL CODE MODEL CODE

R35.3.03.R.0 C8511205 R35.3.03.0.R C8511200

R35.3.04.R.0 C8511206

R35.3.04.0.R C8511201

R35.3.05.R.0 C8511207

R35.3.05.0.R C8511202

R35.3.07.R.0 C8511208 R35.3.07.0.R C8511203

R35.3.10.R.0 C8511209 R35.3.10.0.R C8511204

R35.5

MODEL CODE MODEL CODE

R35.5.03.R.0 C8512205 R35.5.03.0.R C8512200

R35.5.04.R.0 C8512206 R35.5.04.0.R C8512201

R35.5.05.R.0 C8512207 R35.5.05.0.R C8512202

R35.5.07.R.0 C8512208 R35.5.07.0.R C8512203

R35.5.10.R.0 C8512209 R35.5.10.0.R C8512204

Remote Sensing

R= Standard on 535SE Control Box

0= Not available on 536SE Control Box

24 volt Thermostat Terminals

R= Standard on 536SE Control Box

= Not Available on 535SE Control Box

Useable Air Tube Length

See TABLE A on p

age 3.

Firing Rate Range

3= 0.60 – 1.10 GPH

= 0.75

–

1.60 GPH

F D A

Ø B

TECHNICAL DATA

DIMENSIONS – FIG.1

A B C D E F

3 1/2 8 5/16 8 5/16 11 7/8 9 3/8

Inches

See

Tab. A 89 211 211 301 237

DIMENSIONS – FIG.2

A B C D E F

3 5/8 5 1/2 7 1/2 8 7/16 7 1/16 7/16

Inches

mm 92 140 190 215 180 11.2

TABLE A USEABLE AIR TUBE LENGTH

R35.3 R35.5BURNER

MODEL Inches mm Inches mm

.03 3 ¼ 82 3 1/8 80

.04 4 7/16 112 4 5/16 110

* .05 5 11/16 145 5 5/8 143

* .07 7 ¾ 196 7 5/8 194

* .10 10 1/8 257

10 255

* length can be increased approximately

1” by using available fixed flange.

Note: Useable length includes 4mm standard gasket

- Models .03 & .04 fixed flange standard

- Models .05, .07 & .10 adjustable flange standard

30º

45º

60º

FIG. 1

FIG. 2

SPECIFICATIONS R35.3 R35.5

FUEL No. 2 Fuel Oil

Gph 0.60 – 1.10 0.75 – 1.60

FIRING RATE Kg/h 1.89 – 3.5 2.4 – 5.0

Btu/h 81,200 – 154,000 105,200 – 224,000

EFECTIVE OUTPUT kW 23.8 - 45 30.8 – 65.5

VOLTAGE Single Phase 120V 60Hz (+10% - 15%)

POWER CONSUMPTION 130 W 140 W

MOTOR (Rated) 3250 rpm

MOTOR CURRENT (Rated) 2.2 A 2.2 A

CAPACITOR 10 µF – 260 V

PUMP PRESSURE (max.) 200 PSI

PRIMARY CONTROL 536 SE – 535 SE

IGNITION TRANSFORMER 8 kV 16 mA

COMPONENT IDENTIFICATION

1. Thermostat connection terminals

(536 only)

10. Air tube

2. Vacuum gauge connection port 11. Air damper adjustment screw

3. Inlet fuel line port 12. Photocell

4. Return fuel line port 13. Drawer assembly

5. Bleeder / Pressure gauge connection port 14. Lockout lamp ( 535 only ) &

Reset button

6. Pump pressure regulator adj. Screw 15. Primary safety control

7. Electrical enclosure 16. Fuel pump

8. Capacitor (hidden) 17. Motor

9. Mounting flange & gasket

12 13 14

5 6 7

10111

FIG. 3

MOUNTING THE BURNER

There are three possible methods to mount the burner, depending on the individual

application. These are:

1.) Fixed UNIVERSAL FLANGE bolted to the boiler/furnace unit.

2.) ADJUSTABLE FLANGE bolted to the boiler / furnace unit.

3.) ADJUSTABLE FLANGE or fixed UNIVERSAL FLANGE mounted directly to optional

Pedestal kit (C7001022) must be ordered separately.

METHOD 1. (ref. FIG. 5)

A.) Remove the 4 screws (1) from the burner

chassis. Position the UNIVERSAL

MOUNTING FLANGE (2) with

countersunk mounting holes (4) facing

away from burner. Insert the 4 screws (1)

through the countersunk mounting holes

and secure in place.

B.) Position MOUNTING GASKET (3)

between the MOUNTING FLANGE and

the appliance plate. Line up the holes in the

MOUNTING FLANGE with the studs on

the appliance mounting plate and securely

bolt in place.

B B

FIG. 4

DRY

BASE BOILER

COMBUSTION

CHAMBER

FIG. 5

1 2

METHOD 2. (ref. FIG. 6)

A.) Secure the ADJUSTABLE FLANGE

(1) to the burner AIR TUBE by

tightening the bolt (2). Be sure that

the ADJUSTABLE COLLAR is

properly positioned so the outside

edge of the END CONE will be at

least ¼ inch (6.5 mm) back from the

inside wall of the refractory of the

combustion chamber (see dimension

B in FIG. 4 above). The measured

length (A), is to the face of the

MOUNTING GASKET.

B.) Secure the burner to the appliance as

per METHOD 1-B.

METHOD 3. PEDESTAL MOUNT

Secure the MOUNTING FLANGE to MOUNTING PEDESTAL using the hardware provided

with the pedestal. Secure burner to MOUNTING FLANGE as in METHOD 1 and 2.

SERIAL NUMBER IDENTIFICATION

The Riello 15 character serial number, example, 97 A 8511111 00025, is identified as follows: 97 = last two

digits of the year of manufacture; A = BI-week of manufacture; 8511111 = burner product code; 00025 =

increment of 1 for each burner produced – specific to product code – reset to zero each January 1

(97) (A) (851111) (00025)

WARNING: WHEN THE COMBUSTION CHAMBER IS LINED WITH A

REFRACTORY MATERIAL, IT IS IMPERATIVE THAT THE END CONE NOT

PROTRUDE INTO THE CHAMBER AREA, AS EXCESSIVE HEAT COULD

DAMAGE THE END CONE.

FIG. 6

Year of Manufacture BI-week of manufacture Burner product code Sequence

ELECTRICAL CONNECTIONS

To gain access to the line voltage terminals on the primary safety control follow items A and

B below.

A.) Remove drawer assembly from the burner.

B.) Remove the electrical enclosure by removing the three screws. FIG. 3 (7).

C.) Make electrical connections to burner as shown in FIG. 7.

D.) Replace the electrical enclosure over the terminals on the control box and secure using

three screws.

1. Wire Access Hole (Use BX connector)

2. Ground Terminal (Green/Copper Wire)

3. Line (Phase) Terminal (Black Wire)

4. Neutral Terminal (White Wire)

5. Remote Lockout Terminal (535 SE Only)

6. Control Box Mounting Screw

7. 24 V Thermostat Terminals (536 SE Only)

8. Power Supply

FIELD WIRING

Burner operation is controlled by using a low voltage control (24 Vac) with the standard

536SE CONTROL BOX. On some OEM applications, burner operation may be controlled by

using a line voltage (120 Vac) control with the 535SE CONTROL BOX.

The 536SE CONTROL BOX can also be used in a line voltage circuit, by using a WIRE

JUMPER between the 24 V thermostat terminals on the 536SE CONTROL BOX.

Using the appropriate drawing below and on the next page, complete the required field

application wiring to control the burner. All wiring must be done in accordance with local

codes or, in the absence of local codes, with the National Electrical Code ANSI/NFPA 70-

1990 and the CSA Electrical Code.

536SE CONTROL BOX

F F

Photocell

Oil valve

Motor

Capacitor

Black

White

Blue

CONTROL BOX

536SE

Ground

Regulating thermostat

(24V 0.2A)

Limit thermostat

15A max.

Switch with fuse

Neutral

120V ~ 60Hz

WARNING

Do not exchange neutral

with phase.

CARRIED-OUT IN

THE FACTORY

FIELD WIRING

FIG. 8

535SE CONTROL BOX

REMOTE SENSING OF SAFETY LOCKOUT SWITCH 535SE

CONTROL BOX

The SAFETY SWITCH on the 535SE CONTROL BOX is equipped with a contact allowing

remote sensing of burner lockout. The electrical connection is located on the CONTROL

BOX terminal ⊗FIG. 7 (5) as indicated. Should burner lockout occur, the 535SE CONTROL

BOX will supply a power source of 120 Vac to the connection terminal.

NOTE: The maximum allowable current draw on this terminal (5) is 1 A.

WARNING: The terminal ⊗FIG. 7 (5) is to be used only for the connection of a remote

sensing device. If a neutral or ground lead is connected to this terminal, the CONTROL BOX

on the burner will be damaged should lockout occur.

F F

Photocell

Oil valve

Motor

Capacitor

Black

White

Blue

CONTROL BOX

535SE

Ground

Limit thermostat

15A max.

Switch with fuse

Neutral

120V ~ 60Hz

WARNING

Do not exchange neutral

with phase.

CARRIED-OUT IN

THE FACTORY

Regulating

thermostat

Remote lockout lamp

FIELD WIRING

FIG. 9

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