Riello Direct Vent Burner User Manual - Weil
Contents
1. 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 9 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 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 3398 3 64 1 5 32 to 13 64 or 4 to 5 mm GB 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 All pump port threads are Brit ish Parallel Thread design Direct connection of NPT threads to the pump will dam age the pump body Riello manometers and vacuum gauges do not require any adapters and can be safely connected to the pu2. Sep A aba aea bus D dew ee 8 Single line Gravity feed system 8 Two line CUTTS Y SUC WIN rre xe Seat uate ss he hae ll A A AS A A nt ee de ad ei eRe a Y ub 8 SETTING THE AIR ADJUSTMENT PLAT Bain uay dad eee coal bed Bees ka k id 8 COMBUSTION CHAMBER PRESSURE CHART usu u pastuta aqha la cae k Sua 9 BURNER SETUP CHARY s ostias ei Aa Sa mua amuta a Was oir 9 BURINER STAN YOLE tadas riada ni cu amb re ai aa iris 10 TROUBLE SHOOTING CHART l l ua usss aaa aaa aoa ce kabila te ua QL S bu ana desde bad 11 A TYPICAL LAYOUT FOR BF BURNERINTAKEAIR 12 EXPLODED SPARE PARIS LIS 0 kt suya paykuaa se eee AAA AAA amu ae 13 A sanku aa he a eon Bes eo ee umu us mamy ee eh tg Da Bol ae 14 BURNER STARTUPS IS ry t iaa pp ia aii Sa al Suds Su mk dde io cad 15 3398 GB 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 Quantity Description Code 1 Burner with combustion head mounted 1 Mounting gasket C6880016 1 Parts bag C7001060 C7001038 1 Installation manual C6501073 Parts bag C7001060 C7001038 Quantity Description 1 NPT NPTF pipe adapter 1 3 8 straight connector 2 Anti shorts bushings 3 Wire nuts SERIAL NUMBER IDENTIFICATION The Riello 15 character serial number example 06 A 8511111 0002
3. 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 3398 GB TABLE OF CONTENTS PACKAGE CONTENTS lez sermones rie ae eer ee aW ankuta deere ste Su siz 1 SERIAL NUMBER IDENTIFICATION 1 TECHNICAL DATA cross eee eee e A a Bok 2 Pelican si A a a oie cana 2 Burner and mounting flange dimensions o 0 nee nas 2 Burner components identification eee eee eens 2 MOUNTING THE BURNER IO BOILER ii adel ach accutane arate A bw te we oe 3 ELECTRICAL CONNEG TIONS 4 2 5 49 ce ltuy uba ia Dilla Sade Grech it aad aes ia beer Sada ee 3 APPLICATION FIELD WIRING 4 INSERTION REMOVAL OF DRAWER ASSEMBLY 5 PLECTRODE SETIJINGD ci pusu idad desde a iso u ba Q ch ch kb ed dd dino kutay a t hal dette dd 5 NOZZLE PLACEMENT als dro S a Su Saa A a A e bap D uE ie S us Ska 5 TURBULATOR SETTING ira 5 IEEE CONNECTIONS us esop so a o EA A A k a Sik usya s 6 Single line Gravity feed system ee eee ene eee ee eee nes 6 NET NPT ppe adapt r cnn tenets uy S acid a masus SASS HS Ra A Ee BOE ess 7 TWO SS u p uyu c luzulina au aces Wd hae Ra a an ee Phe a aka hae s 7 PUMPE PURGE T uz sani pasaika ui rake a andedicocie Q Dh debs ala psd dm
4. lamp D7526 12sec 2min 12sec 58sec 3398 10 GB TROUBLE SHOOTING CHART 3398 Thermostat is calling for hea Burner is not running Reset Control Box Burner Starts Burner Does Not Start Test for 120Vac Supply at sub base between L P amp N or terminals 43 8 5 120 Vac No Voltage e Check system fuse ensure service switch is ON e Verify all control limits are closed e If using switching relay verify 24Vac at T T Turn off power supply Remove control box and jumper terminals 5 amp 6 Restore power Motor Runs Motor Does Not Run e Verify electrical connections e Check for seized pump motor or fan against housing e Defective motor capacitor e Thermal overload Hot motor e Verify reduced voltage 42 52 Vac between terminals 3 7 e Ensure good contact between control box spades and sub base terminals e Defective control box Replace Burner stays in Pre purge e Faulty CAD cell or seeing light before trial for ignition e Coil wire on terminals 1 amp 2 or 1 amp 8 reversed Open coil circuit terminals 2 amp 8 e Open coil circuit terminal 1 530 SE only Open coil circuit terminal 1 483 SE only will cause burner to cycle normally but burner will lockout e Defective 42 52 Vac supply Terminals 3 amp 7 e Defective control box Replace Burner Continues to Purge and Lightoff with Immediate Flame Dropout 53
5. 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
6. 0 SE Onl e Metal yoke for coil missing e Coil wire 2 amp 8 reversed e Low resistance of coil holding circuit terminals 1 amp 2 1350 ohms 10 Burner Locks Out After Trial For Ignition e Low resistance or no contact on starting circuit of coil terminals 2 amp 8 1 3 ohm 10 e No oil supply tank empty valve closed dirty filter damaged supply lines e Defective or dirty oil valve stem nozzle or pump strainer e Broken pump drive key defective pump no oil pressure e Ignition electrodes shorted cracked porcelain e Burner motor not up to speed e Excessive draft over fire e Defective control box Replace Burner Fires Cycles On amp Off In Quick Succession 483SE Onl e Metal yoke for coil missing e Low resistance or short in holding circuit of coil terminal 1 amp 2 e Coil wires on terminals 2 amp 8 reversed 11 GB A TYPICAL LAYOUT FOR BF BURNER INTAKE AIR A Use an approved air intake kit B Always keep intake air run to the minimum C Maximum intake air run of 4 inch diameter flexible or rigid type of venting 100 D Reduce intake air length by 10 for every 90 elbow used 5 for every 45 elbow used E It is suggested that air intake venting be insulated with R7 min foil lined insulation a minimum of 10 from air intake source Prevent condensation or corrosion of intake air venting F Used approved type of intake air vacuum breaker and t
7. 19313 ONI1113 431dWdAV 8 39N1 AlddNS TIO 134SV9 ONILNNOW 3SNV l4 J 18V3AOIN JlV id LNOdd 43N4N TI39O01OHd O ASOES TOYLNOO AYVINldd ASVd ans IOYULNOOS A4VINldd 31W1d 43109 398N1 dlV YOLOW AJA AAW dAAd dNNd MOO LAN YANIVLAY ANY 1349VW48 N TOO dl 8 S YHAHSVM IWLSAW 418VHS 1dO9 ONILLIA LAILNO 31ZZON qdAMO1WALS JAVA SNId O add WALS INTVA DNIS O dANIVLAYd WALS JAVA 31V ld WALS INTVA N3349S dWNd d3AO9 dWNd S SNId O N ddOS YOLVINDAY YOLVINSDAY AYNSSAYd dNWNd SNId O d3033 18 Ql 8 d3HSVA IV1dIN 318 VHSN4O dJAOO MOVE ddNd 18 NOIlldldOS3d 349 LEElLOOLD 62010029 20001029 SLOLLL89D S 8800 902Z00 80ZS00 vrssooe LcO800 L89000 089200 39200 698500 y30800 8y3030 c 6000 6Z20800 083300 ZSLLOOE 8Zcc00E 9LEZ00E r8S00 evv000 c08200 6 Z 008 SS900 Z80Z00 L8SZO0E 9S1200 6c0Z00 03400 S 69008 61Z4500 c91200 03200 820Z00 89SZ00 ZLOZO0 3009 86EE 8 Le 9 G ve c Le 0g 6c 8c Z 9c Ge vc Ed GG lo Oc 6 O OT QN Q NY O OMNO Sl Y A TA A TO AS A CN F LO ONO O 1SI SLAVd AdVdS 3398 35 Pond Park Rd Hingham MA 02043 Phone 781 749 8292 Toll Free 800 992 7637 Fax 781 740 2069 Burner S N or Model Installer name Company Address Phone Owner Name Address Phone Nozzle
8. 5 is identified as follows 06 A 8511111 00025 06 Last two digits of the year of manu facture A Bl week of manufacture Year of Bl week of Burner 8511111 Burner product code manufacture manufacture product code 00025 Increment of 1 for each burner pro duced specific to product code reset to zero each January 15 3398 GB TECHNICAL DATA SPECIFICATIONS capone 192 Was O Oooo Motor ated E no E BURNER AND MOUNTING FLANGE DIMENSIONS mm 249 266 193 89 n7 220 BURNER COMPONENTS IDENTIFICATION 3 9146 5 946 141mm_ 7 9 46 192 mm 8 1 9 216 mm D7516 BURNER COMPONENTS Lockout indicator lamp and reset button Primary control Primary control sub base Pump pressure regulator Post purge timer Air adjustment Capacitor Combustion head Mounting gasket 10 Universal mounting flange gt lt 11 Turbolator adjustment screw da 12 Coil S452 7 4 15 13 Bleeder and pressure gauge port YP IE 7 i Return fuel line port D8174 OO O QI gt G N AN Vu w SY ale s R Inlet fuel line port 16 Pump 14 u 13 17 Air pressure switch 3398 GB MOUNTING THE BURNER TO THE BOILER Position the MOUNTING GASKET 2 be tween the flat surface of the UNIVERSAL MOUNTING FLANGE 1 installed on the burner and the appliance Line u
9. BASE Should lockout occur the 5305E 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 WARNING If a neutral or ground lead is attached to this terminal the CONTROL BOX on the burner will be damaged should lockout occur 3398 Earth L2 Ground L1 Fuse 15 A SAFETY Switches LIMIT Q Switches FIELD m x WIRING z x D O al RI BI FACTORY WIRED SUB BASE BLACK GREEN AIR PRESSURE Z SWITCH Ground Control Box 530 SE C RED AL 1009 1 Burner Fan Off Timer GB INSTALLATION REMOVAL OF DRAWER ASSEMBLY Removal A Remove the air pressure switch support 6 from the front shield by the two retain Ing screws 7 B Loosen off oil delivery tube nut from pump C Loosen SCREW 3 and then unplug CONTROL BOX 1 by carefully pulling it back and then up D Remove the AIR TUBE COVER PLATE 5 by loosening the retaining SCREW 4 Two SCREWS Model BF5 E Loosen SCREW 2 and then slide the complete drawer assembly out of the combustion head as shown F To insert drawer assembly reverse the procedure in items A to E above ELECTRODE SETTING 5 32 or 4 mm IMPORTANT These dimensions must be observed and verified F NOZZLE PLACEMENT Remove the NOZZLE ADAPTER 2 from the DRAWER ASSEMBLY by loosening the SCREW 1 Insert the proper NOZZLE into the NOZZLE ADAPTER and
10. RIELLO BURNERS Installation amp Operating Manual Single stage operation oil burners 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 RETROFIT APPLICATIONS ONLY A If this burner is being installed in a packaged unit ie burner comes with a boiler or furnace follow This burner is not equipped for 2 line operation For 2 line operation order part 4 C7001025 for BF3 C7001026 for BF5 Um WJEIL MCLAIN Meta RIELLO 40 BF CODE MODEL TYPE C8512352 800060000 Brn PO Rie BF5 1 00GPH Vnt D C8512353 800061000 Brn PO Rie BF5 1 20GPH Vnt D C8512354 800062000 Brn PO Rie BF5 1 40GPH Vnt D C6501073 0 WM 550 142 007 1108 BF5 GB A 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 room is enclosed lt may be necessary to create a window to permit sufficient air to enter the boiler
11. as 20 6 65 To install the by pass plug lm 1 Remove the return plug 7 2 Install the by pass plug 4 using the 2 5 mm hexagonal key 3 Connect the return line connection pipe to the return port 7 of the pump and tighten securely 0 0 0 0 115 100 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 3398 GB 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 O A SINGLE LINE GRAVITY FEED SYSTEM 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 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
12. info Air setting Draft overfire CO CO Single line GB 2165 Meadowpine Blvd RIELLO Mississauga On L5H 3R2 Phone 905 542 0303 Toll Free 800 387 3898 BURNERS Fax 905 542 1525 BURNER START UP FORM Appliance Installation date Fax E mail Burner Start up Info OIL Pump pressure Turbolator setting Draft breech Oo Smoke density Bacharach _ 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 15 RIELLO BURNERS 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
13. l No pipe sealant is required since this thread is self sealing 2 Ensure that the brass adapter is tightly fitting into the steel adapter Retaining nut 3 Fit the pipe or fitting used to connect the oil supply system into the brass adapter D7522 Use pipe sealant to ensure a leak free joint TWO LINE LIFT SYSTEM Accessory package required If a two line system is required install the By pass plug The by pass plug is installed in the return port of the pump A 2 5 mm hexagonal key is to be used to install the plug DO NOT use an inch size hexagonal key damage to the by pass plug may result A Suction and return lines should be sized in accordance with local codes The suction line should extend down near the bottom of the oil tank The return line should terminate near the top of the oil tank B Suction and return lines should be sized in accordance with local codes 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 table Install the required fittings NPT THREAD in the SUCTION LINE and RETURN LINE CONNECTION FITTINGS Attach the required tubing to these fittings n 3eOD 2 oD FT 100 Purse 30 10 80 25 330 100 pipe lengths 50 15 65 20 295 90 indicated in chart 50 70 Los 30 25 8 100 3
14. mp ports An NPT metric adapter must be used when connecting other gauge models SINGLE LINE GRAVITY FEED SYSTEM 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 Install the required fitting NPTF to NPT adapter into the pump s SUCTION LINE CONNECTION FITTING on left side of burner on top Attach the required tubing to this fitting Be sure that the plug in the RETURN LINE CONNECTION FITTING is tightened securely W o wro res 20 198 60 325 100 ne y 3398 GB NPTF NPT pipe adapter The BF burner you have purchased is shipped with an NPTF to NPT fitting This fitting is the connection point for the oil line edi C AN from the oil tank or the in line oil filter In some locations fit tings with the NPTF male thread are difficult to obtain In these areas a more common NPT thread male fitting or pipe may be used To accommodate this NPT thread the BF NPT NPTF adapter is supplied This brass adapter iS Bulkhead fitting installed as shown below Installation of NPT NPTF pipe adapter 1 The brass adapter may be threaded directly into the steel female fitting already installed in the BF burner chassis BF burner chassis wal
15. o be installed in the same room and the burner for the event of intake air source being blocked this device should be tested to prove that in the event of intake air source is blocked that the vacuum breaker balancer is set correctly and can provide sufficient air for combustion for the burner If the room that the burner is installed into cannot provide enough air or air quality is a concern an additional air inlet source will have to be providing to this room THIS INTAKE AIR LAYOUT FOR CHIMNEY APPLICATIONS ONLY urner installation example for retrofit applications Combustion Air In F L ks APPROVED FRESH AIR _ INTAKE KIT VACUUM BREAKER OR APPROVED EQUIVALENT ADBF BURNER 3398 12 EXPLODED SPARE PARTS LIST 3398 13 313 1d4INOO S 7 AUTO TAM LES SAA SSINYWVH INIJIM 9M 0 GON VON HOLIMS JYNSSIYA HIY 9M 9 0 EON HOLIMS IYNSSIYUA HIV 11M 39 1430 ADYNd LSOd 6001 TV JgNL WO TIZZON d31dVGV 31ZZON LYOddNS 3040419313 osiad YOLVINEYNL MANASSV 300419313 MANASSV YOLVINDAY NOILdlYOSAd sdg 0 100Z9 Z 00Zz SO 9S0Zz SO SS0Z88 SO v8010029 98200 S96900 9969008 226900 1688008 1982008 3009 8v LV OV 9y GV vv eV ov LV OV 6 ON dlya 91d NVd dn SZL YOLIDVAVI AINO 38N1 S r GAC HA 18S 949 AJdANVO div dO V 1 1S43d YAdWNVd HIV IVANVIA d3AO9 ddNtd08 1LIASVOD 13534 Y43IN4M9 DNINIdO0 dd3AOO 1 d4IN 1d NIWI13940d 3004
16. p the holes in the UNIVERSAL MOUNTING FLANGE with the STUDS 3 on the appliance mounting plate and securely bolt the UNIVERSAL MOUNT ING FLANGE to the plate To remove the burner from the boiler re verse the procedure E9328 ELECTRICAL CONNECTIONS It is advisable to leave the control box off the sub base while com pleting the electrical connection to the burner 1 Wire access hole Use BX electrical connector 2 Earth ground conductor terminal Green wire 3 Hot conductor terminal Black wire 4 Neutral conductor terminal White wire WARNING The hot black wire must be connected to the L terminal and the neutral white wire must be connected to the N terminal or the primary safety control will be damaged Do not connect wither wire to the terminal marked Q Using the appropriate diagram below make electrical connec tions to burner All wiring must be done in accordance with existing electrical codes both national and local When all electrical connections have been made the control box may be put back in place on the sub base WARNING DO NOT activate burner until proper oil line connections have been made or failure of the pump shaft seal may occur 3398 GB APPLICATION FIELD WIRING REMOTE SENSING OF SAFETY LOCKOUT The SAFETY SWITCH in the 530SE CONTROL BOX is equipped with a contact allowing remote sensing of burner lockout The electrical connection is made at terminal 4 e on the SUB
17. plug on the top right hand side of the cover Turn the screw counter clockwise indicator to increase com bustion air turn the screw clockwise indicator to decrease combustion air C The final position of the air damper will vary on each installation Use instruments to establish the proper settings for maximum CO and a smoke reading of zero NOTE Variations in flue gas smoke CO2 and temperature readings may be experienced when the burner cover is put in place Therefore the burner cover must be in place when making the final combustion instrument readings to ensure proper test results 3398 COMBUSTION CHAMBER PRESSURE CHART CHAMBER PRESSURE 3398 INCHES WC BURNER OUTPUT VS CHAMBER PRESSURE CHART 0 5 ss 0 3 0 2 0 1 ps 0 0 0 50 0 75 1 00 1 25 1 50 1 75 GPH BURNER OUTPUT RIELLO BURNER SET UP SHEET Weil McLain Part No 8000 60000 8000 61000 8000 62000 Riello Part No C8512352 Burner Model Series preset 1 input GP 08 10 Turbolator Seting o 1 Air Gate Setting Ait tube insertion 4 1 4 4 1 4 1 Nozzle pre installed at factory C8512353 C8512354 BFS Factory BF5 Factory preset 1 preset 1 U0s US 1 4 1 00 X70 1 10 X70 B 41 4 4 1 4 GB GB BURNER START UP CYCLE Normal Lock out due to light failure Thermostat mMm Motor n Ignition transformer p i Valve Flame Lock out
18. 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 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 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 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 A The initial air damper setting is made by turning screw 2 until the top edge of the air damper 3 is aligned with the number ac cording to the burner setup chart B Further adjustments can be made with the burner cover in place by removing plastic
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