Riello 40 F3 Technical data
Contents
1. ElecrodePoreeln 4s 3008828 ArTubeony 300752 _ Air Tube only 3008626 ArTubeony 3007594 ArTubeoly 8 7 8 COMBUSTION HEAD COMBUSTION HEAD 40 3048877 Combustion Heada 7 8 3948874 Long Combustion Head 10 27172 3o48975 Combustion Head 8 7 8 3945974 Long Combustion Head 10 27172 41 300958 Turbulator Diss 4 300098 TubuatrDisc 3008977 TurbulatorDiss 300977 TwbuatrDsc 42 3006966 Electrode Support 42 3006966 Electrode Support 3006965 Nozzle Adapter 43 3006965 Nozzle Adapter 44 3008790 Nozzle Oil Tube 300870 NezzeOiTube Long 3008628 Nozzle OilTube 300974 NozzeOlTube Long gee a en 3008685 Regulator Assembly 3005878 Regulator Assembly Long 4g 3008789 Electrode Assembly 3005870 Electrode Assemby Long 3008632 Electrode Assembly 3005880 Eectrode Assembly Long 47 3005869 Electrode Porcelain 47 3005869 EectrodePorcelan 3008788 Air Tube only 30093 ArTubeony Euer 48 3008828 ArTubeony 300788 mr C6501000 F3 F5 I O manual Rev4 3 20 dL 1 RIELLO 35 Pond Park Rd 2165 Meadowpine Blvd Hingham MA 02043 em Mississauga On L2. Amulet Cerafell Sleeve Kt 2030029 cl 3 21 70010101 Pump 50 7001085 TypeL24voltswitchingrelay 2 3000443 PumpDieky LLL 23 c7001034 SSCS Oe 3007316 Arrubecover 51 2623141 Capilaryportpug 25 3002280 Photocel 52 300032 Adjustable Steel Flange l1 VSBT COMBUSTION HEAD SHORT COMBUSTION HEAD 3948876 VSBT Combustion Head 3 3948873 Short Combustion Head 6 271T1 3048976 VSBT Combustion Head 3 3945973 Short Combustion Head 6 271T1 ier map 3006977 Twbuatrbisc 300977 TurbuetorDise C 42 3006966 Electrode Support 42 3006966 Electrode Support 43 3006965 Nozzle Adapter 43 3006965 Nozzle Adapter 44 3008827 Nozzle Oil Tube 300098 Nozze Oil Tube Shot 3008628 NozzeOiTue 3006973 Nozzle Shot 4g 3008658 Regulator Assembly 4 3006824 Regulator Assembly Shot 3008634 Regulator Assembly 3006325 Regulator Assembly Shot ne 3008631 Electrode Assembly 3006329 Electrode Assembly Short 47 3005869 Electrode Porcelain 47 3005869
3. 215mm C6501000 F3 F5 I O manual Rev4 3 RIELLO 40 F5 TECHNICAL DATA DIMENSIONS MODEL F5 A B Inches 9 11 64 10 11 16 7 3 32 31 2 9 13 32 233 272 180 89 239 1 10 inch long 254mm tubes are also available SPECIFICATIONS NO heavier than 2 FUEL OIL E ele ee a a 0 75 to 1 65 US GPH IGNITION TRANSFORMER MOUNTING FLANGE DIMENSIONS a c 3 31 32 101mm 5 1 2 140mm 7 1 2 190mm 8 15 32 215mm C6501000 F3 F5 I O manual Rev4 3 OIL BURNER COMPONENTS IDENTIFICATION STANDARD RIELLO OIL BURNER MODELS 40 F3 amp 40 F5 BURNER KEY COMPONENTS 1 530 SE C INTEGRATED PRIMARY CONTROL 7 ELECTRONIC AIR SHUTTER ASSY 2 PRIMARY CONTROL SUB BASE 8 WIRE HARNESS FOR AIR SHUTTER 3 FUEL UNIT PUMP 9 COMBUSTION HEAD WITH DRAWER ASSY 4 PSC MOTOR 10 SEMI FLANGE 2 PIECES 5 CAPACITOR 11 UNIVERSAL MOUNTING FLANGE amp GASKET 6 AIR ADJUSTMENT AND SHUTTER 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 BlI week of manufacture 8511111 burner product code 00025 increment of 1 for each burner produced specific to product code reset to ze
4. 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 5 FO manual Rev4_3 22 C6501000 5 1 manual 4_3 23 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 C6501000 F3 F5 FO manual Rev4 3 24
5. for each part No CODE j F3 F5 DESCRIPTION No CODE DESCRIPTION peg supp ox cpm eee ee 8 3007233 BumerBackCover 27 3005854 Semi Flange 2 Required 2 3006992 Pipe Connector Supply 28 3005855 Universal Mounting Fange 30657 3 NPTMetrcAdapter Male 29 3005856 Mounting Gasket 3006993 Pipe Connector sg C7001081 F3 replacement air damper kt 5 300584 NPT Metric Adapter Female C7001082 Fbreplacementairdamperkt 6 3007077 CrtushableMetalWasheri amp ID 7 3058 __ Bede f E 8 3007028 O Ring Pump Pressure Regulator Fe 9 300202 Regulator Screw 34 30727 Arintake Housng 10 C7010002 O Ring Pump Cover 3007162 3007208 Arintake Housing 11 3005719 Pumpsoee 35 300844 Capactor125pF 12 3006925 VaveStm 36 Fan 13 3007208 Valve Stem Plale 06950050 AcoustcLiner 14 3007029 _O Ring Valve Stem Upper 3007320 AcousticLiner ep E E E O e l o 16 3007268 Nozzle OutetFitng 3007222 Chassis FrontPate r 3007087 Crushable Metal Washer sD 18 3002278 Primary Control Sub Base OPTIONAL 19 3006553 CollUBracketandKnurledNut 49 C7001033
6. 5H R2 Phone 781 749 8292 Phone 905 542 0303 Toll Free 800 992 7637 BURNERS 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 Installation Company date 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 Turbulator Air Setting setting Draft Draft Over fire breech Smoke density Bacharach Single Two Line pressure Air Setting Head Setting Draft Draft Over fire breech CO CO Manifold pressure lonization Reading Input HAd c BTU Hr This form was designed and provided in 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 C6501000 5 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 mu
7. NER 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 1 manual Rev4 3 6 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 DRY BASE BOILER COMBUSTION CHAMBER 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 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 i
8. Riello Burner Installation Instructions for Weil McLain Cold Oil Boilers WARNINC Fallure to follow the information below can result in severe personal injury death or substantial property damage Instructions are for use only by a qualified installer service technician Read all boiler and burner instructions before proceeding Follow instructions in proper order Turn off service switch to boller and any other electrical disconnect switches General installation Instructions 1 Connect harness to boder wiring using plug to plug connector 2 Pull any excess harness away from boiler junction box and tighten clamp to hold hamess in place eel Route harness away from burner door to avoid excess heat 3 For SGO applications additional switching relay WM part number bas abo needs lo be utilized 4 Setup burner according to instructions in Riello Burner Manual Also see below recommended settings Bumer Air Shutter EH PSIG Setting Delavan 0 60 60B Hago 0 60 60 ES Delavan 0 75 60B Hago 0 75 60 ES Delavan 1 00 60B Hago 1 00 WES Delavan 1 25 GB Hago 1 25 MES RIELLO BURNERS D RIELLO 40 SERIES MODELS 40 F3 amp F5 EQUIPPED WITH ELECTRONIC AIR SHUTTER INSTALLATION amp 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 o
9. TMENT TABLES pp 15 AMULET INSTALLATION INSTRUCTIONS Ne 16 SEQUENCE OF OPERATIONS daar aaa 17 amp 18 EXPLODED PARTS VIEW sessed 19 PARTS LIS T iiti d co red alveo a dti e iuc Hired ect 20 START UP FORM ro ida ica 21 INSTALLATION PRECAUTIONS Sa 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 2 Mounting flange bolts short 1 Burner chassis with cover 2 Semi flange bolts long 1 Universal Mounting Flange 4 Nuts 2 Semi flanges 2 Chrome nuts l Mounting gasket 1 Oil pump connector supply 1 Installation Manual l Oil pump connector return l By pass plug 1 Female 4 NPT adapter 1 Male 3 8 adapter Separate carton 1 2 5 mm Allen key l Combustion Head OEM burners shipped with combustion head mounted C6501000 F3 F5 I O manual Rev4_3 RIELLO 40 F3 TECHNICAL DATA DIMENSIONS MODEL F3 A B Inches 8 15 32 9 59 64 6 15 32 31 2 8 29 32 215 252 164 89 226 E1 10 inch long 254mm tubes are also available SPECIFICATIONS NO heavier than 2 FUEL OIL E NS aa a de S 0 50 to 0 95 US IGNITION TRANSFORMER MOUNTING FLANGE DIMENSIONS TD 3 31 32 101mm 5 1 2 140mm 7 1 2 190mm 8 15 32
10. VICE WIRED amp SUPPLIED BY OTHERS AUXILIARY SUB BASE ADD ON CONNECTOR AIR SHUTTER T 24 THERMOSTAT CONNECTIONS LOW VOLTAGE OPERATED SYSTEMS MIN WIRE SIZE INSULATED 18AWG 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 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
11. 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 ELECTRIC AIR SHUTTER ASSY SEE FIELD CAPACITOR WIRING LEGEND BROWN WHITE BLUE BLACK 120V SOURCE ACTIVATES SHUTTER OPEN MOTOR LEAD 120V SOURCE 120V CONTROL LOCK OUT ALARM TERMINAL X CONSTANT 120V AUXILIARY TERMINAL ELECTRONIC AIR SHUTTER C6501000 F3 F5 LO 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 24V OPERATED SYSTEMS SHUTTER AIR MOTOR 120VAC 60HZ 120VAC 60HZ WIRING LEGEND PLEASE NOTE OPERATING LIMIT AND SAFETY LIMIT ARE TWO SEPARATE LIMITS MAIN DISCONNECT FUSE MANUAL SERVICE SWITCH 3 SAFETY LIMIT DEVICE 4 OPERATING LIMIT DEVICE EARTH GROUND CONNECTION BURNER CHASSIS 6 BURNER CONTROL REMOTE LOCK OUT ALARM DE
12. crease in pressure gt heat hj heat increase in pressure down air lube due to increase in combustion chamber pressure increase in pressure down air tube due to increase in combustion chamber pressure 6501000 F3 F5 I O manual Rev4 3 tapered combustion chamber causes increase in pressure inside heat heat increase in pressure down air tube due to increase in combustion chamber pressure AMULET HELPS PREVENT HOT GASES FROM TRAVELLING DOWN AIR TUBE RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR SHUTTER NORMAL OPERATIONAL SEQUENCE ELECTRIC AIR SHUTTER CLOSED WAITING FOR CALL FOR HEAT MOTOR PREPURGE SHUTTER An BURNER MOTOR STOPS ELECTRIC AIR SHUTTER CLOSES THERMOSTAT OR LIMIT CONTROL ELECTRIC AIR SHUTTER MODES CONSTANT UNITERUPTED 120V POWER SUPPLY SERIES ORE NER Mele TO ELECTRIC AIR SHUTTER ASSEMBLY 17 C6501000 5 FO manual Rev4_3 RIELLO 40 SERIES OIL BURNER EQUIPPED WITH ELECTRONIC AIR SHUTTER NO FLAME OPERATIONAL SEQUENCE AIR SHUTTER LY OPEN SWITCHES POWER TO BURNER MOTOR MOTOR PREPURGE AIR SHUTTER BURNER MOTOR STOPS ELECTRIC THERMOSTAT OR LIMIT CONTROL ELECTRIC AIR SHUTTER MODES CONSTANT UNITERUPTED 120V POWER SUPPLY 40 SERIES OIL BURNER MODES f 75 ELECTRIC AIR SHUTTER ASSEMBLY 18 C6501000 5 I O manual Rev4_3 C6501000 5 FO manual 4_3 Indicates applicable model
13. e 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 1 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 flue gases tapered combustion chamber causes in
14. ed with the burner for connection to either a single or two line system Also supplied are two ADAPTORS 3 two female 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 PUMP LEGEND PUMP COVER PUMP COVER O RING BSPP TO NPT ADAPTERS SUPPLY AND RETURN OIL LINES RETURN PORT BY PASS SCREW NOZZLE PORT PUMP OULET TO NOZZLE PUMP PRESSURE PORT AND BLEEDER PORT PUMP SUPPLY PORT PUMP RETURN PORT 10 PUMP PRESSURE REGULATING SCREW 11 VACUUM PORT 12 PUMP VALVE STEM ooxoosom C6501000 5 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 B Connect the pipe connector to the SUPPLY PORT 5 of the TRO pump Attach the NPT adapter to the pipe connector NOTE Do not exceed pipe lengths indicated in Attach the required piping to this pipe adapte
15. ir plate adjust arm After adjustments are made please retighten screws 3 amp 5 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 NOTE Variations in flue gas smoke CO 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 FO 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 NOZZLE PUMP RATE 5 x PRESSURE TURBULATOR AIR DAMPER USGPH PSI BAR SETTING SETTING sa aera Pita or a 0 95 75 x 60 80 160 11 0 MODEL F5 BURNER SETUP CHART ACTUAL FIRING NOZZLE PUMP RATE 5 SIZE PRESSURE TURBULATOR AIR DAMPER US GPH SETTING SETTING is 10 00 225 65 x 607807 165 135X60 80 145 10 40 60 NOTE The above set up charts are a starting point only The burner and applianc
16. n 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 SINGLE LINE GRAVITY FEED SYSTEM I Loosen the bleeder valve A until oil flows out Tighten the bleeder valve securely and start burner IL 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 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 WARNING Omitting step
17. nsetting 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 4 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 1 4 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
18. r Be sure that chart the plug in the RETURN PORT 7 is tightened securely TWO LINE LIFT SYSTEM LENGTHS H 380D 1 2 OD 00 0 0 115 35 330 100 30 LO 80 25 330 100 50 15 65 20 295 90 95 30 25 8 100 30 31 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 two C6501000 F3 F5 LO manual Rev4 3 12 line system supply and retum 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 retum 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 o
19. r furnace then follow the settings on the OEM page as settings may differ Burner is set for a single line system C6501000 F3 F5 1 manual Rev4 3 TABLE OF CONTENTS TECHNICAL DATA Model ESSE SSG 3 TECHNICAL DA PA Model Pa 4 OIL BURNER COMPONENT IDENTIFICATION Ne 5 SerialNumber 1 ns e Nus 5 INITIAL SET UP ritus a tees 5 ASSEMBLY OF AIR TUBE TO BURNER CHASSIS Ne 6 MOUNTING BURNER TO BOILER OR FURNACE sese 6 Method 1 Universal Mounting Flange Ne 7 2 5 Collar SASS 7 Mathiod 3 PedestalMOUBIE 8 FACTORY WIRING cios Ran amp APPLIC AA TON FIELD WIRING rq EE aa 9 NOZZLEPIACBNEBNE epu eis 10 INSERTION REMOV AL OF DRAWER ASSEMBLY 1 10 EEBCTRODE SETTING SASSER AL 11 TURBULATOR SETTING stie tun eor seien 11 PUMP CONNECTIONS AND PORT IDENTIFICATION serere 11 Single Line Gravity MECC 12 TO Lane Lil Sy Ste ri ooa o ees cesta eee ee 12 PUMP PURGE oe E 13 single System o ao hie ide vedi ice 13 TWO Line Lift S SUPE SAEED te ve tsa ups ui deli ro ow aru bep eed ds 14 SETTING THE AIR ADJUSTMENT PLATE 14 BURNER ADJUS
20. 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 LO manual Rev4_3 10 ELECTRODE SETTING IMPORTANT THIS DIMENSIONS MUST BE OBSERVED AND VERIFIED 5 32 4mm 5 64 to 7 64 or 2 a 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 specifications shown in this manual MODEL F3 NOTE Zero and four are scale indicators only From left to nght the first line is 3 and the last line 0 MODEL 5 Same as above except scale indicators 0 and 4 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 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 7 for pressure readings Two PIPE CONNECTORS 4 are suppli
21. ro each January 1 99 A 8511111 00025 Bl week of manufacture Burner product code 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 amp 9 then set aside D Mount air tube to burner chassis see next page C6501000 F3 F5 LO 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 BUR
22. s 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 LO 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 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 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 a
23. st 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
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