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American Standard PFWF071A93ABA Installation Manual

Oil fired water boiler with three pass cast iron heat exchanger
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INSTALLATION GUIDE
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
IMPORTANT — This Document is customer property and is to remain with this unit. Please
return to service information pack upon completion of work.
*PFWF071A93ABA
*PFWF099A94ABA
*PFWF132A95ABA
*PFWF164A96ABA
* May be "A" or "T"
Oil Fired Water Boiler
with Three Pass Cast Iron Heat Exchanger
*PFWF201A97ABA
*PFWF242A98ABA
*PFWF286A99ABA
®
C
US
18-CG03D1-4

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Summary of Contents for American Standard PFWF071A93ABA

  • Page 1 ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of work. *PFWF071A93ABA *PFWF201A97ABA *PFWF099A94ABA...

  • Page 2: Safety Considerations

    ▲ ▲ 1.0 Safety Considerations WARNING IMPORTANT: Read this entire manual before BURN HAZARD beginning installation procedures. ALLOW BOILER TO COOL DOWN PRIOR TO Read this manual carefully before attempting to SERVICING OR PERFORMING MAINTENANCE. install, operate, or perform maintenance on this FAILURE TO FOLLOW THIS WARNING COULD unit.
  • Page 3 ▲ ▲ ▲ WARNING WARNING SAFETY HAZARD CARBON MONOXIDE POISONING HAZARD THESE BOILERS ARE NOT APPROVED OR Failure to follow the steps outlined below for each appliance connected to the venting system being INTENDED FOR INSTALLATION IN MANU- placed into operation could result in carbon monoxide FACTURED (MOBILE) HOUSING, TRAILERS, poisoning or death.

  • Page 4: Cautions

    thorized modifi cations made to the boiler, or any The following warning complies with State of California law, Proposition 65. components thereof, or improper installation of ▲ WARNING the boiler in the fi eld. Furthermore, any such fi eld modifi cations VOID THE WARRANTY and place This product contains fiberglass wool insulation! responsibility for safe and reliable operation of the Fiberglass dust and ceramic fibers are believed by the...

  • Page 5: Table Of Contents

    Table of Contents 1.0 Safety considerations ................. 2 1.1 Warnings .........................2 1.2 Cautions ........................4 1.3 Notes ........................4 2.0 Pre-Installation Information & Instructions ..........6 2.1 Parts Included ......................6 2.2 General Specifi cations ..................7 2.3 Codes and Regulations ..................9 2.4 Locations and Clearances ..................9 2.5 Outline Drawings ....................10 3.0 Installation Instructions ................

  • Page 6: Pre-Installation Information & Instructions

    Pressure Temperature Supply Water gauge Thermostat Blank * On / Off Vent Cover Plate for Future Optional Supply Accessory Sight Burner assembly glass mounting holes Swing Door - Factory 1-1/4" Plug installed hinges on right - field convertible to left Boiler Drain Return Boiler Feet...

  • Page 7: General Specifi Cations

    2.2 General Specifi cations Table 1 - General Specifications Model *PFWF071A93ABA *PFWF099A94ABA *PFWF132A95ABA 71,000 99,000 132,000 Input BTU/hr DOE Output BTU/hr 61,000 86,000 115,000 I=B=R Net BTU/hr 53,000 75,000 100,000 Efficiency - AFUE 85.5 85.7 85.9 Electrical Power Supply 115 volts / 1 phase / 60 hertz Minimum Circuit Ampacity - amps less than 12.0...
  • Page 8 Table 1 - General Specifications (Continued) Model *PFWF164A96ABA *PFWF201A97ABA Input BTU/hr 164,000 201,000 DOE BTU/hr 143,000 176,000 I=B=R Net BTU/hr 125,000 153,000 Efficiency - AFUE 86.1 86.3 Electrical Power Supply 115 volts / 1 phase / 60 hertz Minimum Circuit Ampacity - amps less than 12.0 Maximum Overcurrent Protection Nominal Flue Outlet Dia.

  • Page 9: Codes And Regulations

    3. All clearances between the boiler and the 2.3 Codes & Regulations enclosure must equal or exceed the minimum The manufacturer assumes no responsibility for stated in the clearance table on the Outline equipment installed in violation of any code or regu- Drawings.

  • Page 10: Outline Drawings

    2.5 Outline Drawings Figure 2 - Dimensions and Connections 19.68 5.39 5.00 5.39 5.39 All dimensions are in inches Table 3 Model *PFWF071A93ABA 17.0 1 1/4 1 1/4 *PFWF099A94ABA 20.9 1 1/4 1 1/4 *PFWF132A95ABA 24.9 1 1/4...

  • Page 11: Installation Instructions

    clips to the left and right jacket panels. See 3.0 Installation Instructions Figure 7. The metal control enclosure is 3.1 Moving Boiler to Installation Loca- removed from the left and right jacket panels tion by removing two phillips screws on each side.

  • Page 12: Setting Boiler

    3.2 Setting Boiler Boiler Top Panel Verify the fl oor structure where the boiler will be set can support the weight of the boiler. Screw Locate the boiler so all components are pro- tected from water damage during operation. Control As required, raise the boiler above the fl...
  • Page 13 4) The installer of the boiler is required to provide 7) A 3/4” pipe must be routed from the outlet of the pressure relief valve to the nearest suitable drain. a low water cutoff switch when installing the This pipe is not provided with the boiler. boiler above the distribution system.
  • Page 14 I. Typical System Piping Diagrams 18-CG03D1-4...
  • Page 15 18-CG03D1-4...
  • Page 16 18-CG03D1-4...
  • Page 17 18-CG03D1-4...

  • Page 18: Combustion Air And Ventilation

    3.6 Combustion Air and Ventila- tion ▲ ▲ WARNING CONFINED CARBON MONOXIDE POISIONING HAZARD! SPACE VENTILATION REQUIRED! OIL BOILER/BURNER COMBUSTION AIR OPE- LESS THAN 50 CU. FT. NING MUST NOT BE OBSTRUCTED OR BLOC- PER 1000 BTU/HR. INPUT ALL KED. THESE OPENINGS SUPPLY COMBUSTION Figure 8 EQUIP.
  • Page 19 installation codes always take precedence and shall be followed. The content of certain pertinent passages of NFPA UNCONFINED 31, (most recent edition) methods to obtain and SPACE ensure adequate combustion airfl ow to the boiler has been excerpted and, in some cases, paraphrased below for reference purposes.

  • Page 20: Flue / Chimney / Vent Connector

    Full Basement (example of an unconfi ned space): e. *PFWF201 and BAYRBF05ABURNA a. Where a boiler is installed in a full base- (See Direct Vent Instructions section) ment, in a building of conventional construc- tion with normal air infi ltration, infi ltration If an exhaust fan, additional air consuming machi- is normally adequate to provide air for com- nes (e.g.
  • Page 21 The inside area of the chimney liner should equal, at Chimney Inspection minimum, the area of the vent pipe exiting the boiler- The chimney, vent, or any passageway for the stack gases to fl ow to the outdoor atmosphere is a very π...
  • Page 22 If the chimney penetrates a roof more than 10 feet A thimble should be used to connect the vent con- from a ridge, wall or parapet, a minimum of 3 feet nector pipe to the chimney so that the vent connector above roof or exit point must be maintained.
  • Page 23 Table 5 Figure 17 Reduction of Clearances with Specifi ed Forms of Pro- tection Allowable Clearance Type of Protection with Specifi ed Protec- tion (in.) Where the required clear- Applied to and covering all sur- ance with no protection faces of combustible material from the appliance or within the distance specifi...
  • Page 24 PREVENTION OF CHIMNEY CONDENSING: Be sure to use stainless steel liners, such as stainless types 430, 304, or for the toughest corrosion pro- PROPER VENTING REQUIRED! blems, type 316. If the chimney is the correct size for Improper venting may lead to condensation in the the unit and condensing still occurs, then insulating chimney.
  • Page 25 POWER (SIDE-WALL) VENTING G) Use a UL and CSA approved type of intake air ▲ ▲ vacuum breaker. This is to be installed in the same CAUTION room as the burner in the case of the air intake being Manufacturer will NOT assume responsibility for blocked.
  • Page 26 CHIMNEY EXHAUST VENT WITH OUTSIDE COMBUSTION AIR USING BAYRBF BURNER (All venting components field supplied) THIS INTAKE AIR LAYOUT FOR CHIMNEY APPLICATIONS ONLY For Direct Vent Illustrations, see Appendix A Approved Combustion Air Intake Hood BAYDVK10AADPTA Adapter Approved Combustion Air Intake Pipe UL and CSA Approved Vacuum Breaker...

  • Page 27: Boiler Swing Door Conversion

    3.9 Boiler Swing Door Conversion The boiler swing door ships from the factory with hinges installed on the right side of the boiler allowing the door to be opened from the left side. If an application requires the door to open from the right, use the follow- ing instructions to convert the door.
  • Page 28 Figure 23 Figure 24 x Nut x Nut 6. Remove the upper and lower hinges. To 5. Remove door from hinges. remove, rotate the hex nut securing the hinges counter clockwise. Save both threaded rod with hext nut and hinges. Figure 26 Figure 25 Hex Nut...
  • Page 29 Figure 27 Figure 28 10. Replace cotter pins. Proceed with 9. Set the swing door on the hinges while installing burner on swing door. inserting hinge pins saved from step 3. 18-CG03D1-4...

  • Page 30: Oil Burner Installation

    3.9 Oil Burner Installation Instructions PACKAGE LIST Your Riello BAYRAF03ABURNA (F3), BAYRA- Models BAYRAF03ABURNA (F3), BAYRAF05A- F05ABURNA (F5) or BAYRAF10ABURNA (F10) BURNA (F5) and BAYRAF10ABURNA (F10) ▲ burner should include the following parts. Please CAUTION check to make sure all parts are present before be- Before opening the boiler door, disconnect burner ginning the installation.
  • Page 31 Table 7 SPECIFICATIONS MODEL BAYRAF03ABURNA (F3) BAYRAF05ABURNA (F5) BAYRAF10ABURNA (F10) FUEL: NO heavier than #2 FUEL OIL NO heavier than #2 FUEL OIL NO heavier than #2 FUEL OIL FIRING RATE: 0.50 to 0.95 US GPH 0.75 to 1.65 US GPH 1.45 to 2.95 US GPH EFFECTIVE OUTPUT: 70,000 to 133,000 BTU/h...
  • Page 32 Oil Burner Installation Instructions PACKAGE LIST Your Riello BAYRBF03ABURNA (BF3) or Models BAYRBF03ABURNA (BF3) and BAYRBF05ABURNA (BF5) burner should include BAYRBF05ABURNA (BF5) ▲ the following parts. Please check to make sure all CAUTION parts are present before beginning the installation. Before opening the boiler door, disconnect burner cord at the plug.
  • Page 33 Table 9 SPECIFICATIONS MODEL BAYRBF03ABURNA BAYRBF05ABURNA FUEL: No. 2 Fuel Oil No. 2 Fuel Oil FIRING RATE: 0.50 to 0.95 US GPH 0.75 to 1.65 US GPH EFFECTIVE OUTPUT: 70,000 to 133,000 BTU/hr 105,000 to 231,000 BTU/hr VOLTAGE (Single Phase): 120V 60Hz (+10% -15%) 120V 60Hz (+10% -15%) ABSORBED ELECTRICAL POWER: 192 Watts...
  • Page 34 Models BAYRAF03ABURNA, BAYRAF05ABURNA and BAYRAF10ABURNA BURNER COMPONENTS IDENTIFICATION Figure 31 BURNER KEY COMPONENTS FOR BAYRAF03ABURNA, BAYRAF05ABURNA & BAYRAF10ABURNA 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 7.
  • Page 35 Models BAYRBF03ABURNA & BAYRBF05ABURNA BURNER COMPONENTS IDENTIFICATION Figure 32 BURNER KEY COMPONENTS FOR BAYRBF03ABURNA & BAYRBF05ABURNA 1. Lockout Indicator Lamp and Reset Button 2. Primary Control 3. Primary Control Sub-base 4. Pump Pressure Regulator 5. 24V Switching Relay 6. Air Adjustment 7.
  • Page 36 12 11 INTERNAL FACTORY WIRING CONTROL BOX SUB-BASE PUMP VALVE (COIL) MOTOR RIELLO 40 F3, F5, F10 SERIES CAPACITOR OIL BURNER EQUIPPED 2 3 4 5 6 7 8 WITH AN ELECTRONIC AIR SHUTTER INTERNAL FACTORY WIRING AL 1008 24V EARTH SWITCHING GROUND...
  • Page 37 D. REMOVAL OF DRAWER ASSEMBLY INITIAL SET UP NOTE: If further detail is needed, refer to the Riello 1. To remove the drawer assembly, loosen the burner installation guide inside the Riello Burner. screw (3) securing the PRIMARY CONTROL (1) and then unplug by carefully pulling it back and then upward.
  • Page 38 Approved Boiler/Oil Burner Combinations *PFWF071A93ABA *PFWF099A94ABAA *PFWF132A95ABAA *PFWF164A96ABAA *PFWF201A97ABAA Burner Model for 3 Pass Cast Iron for 3 Pass Cast Iron for 3 Pass Cast Iron for 3 Pass Cast Iron for 3 Pass Cast Iron HX, 3 Sections HX, 4 Sections...
  • Page 39 Approved Boiler/Oil Burner Combinations *PFWF099A94ABAA *PFWF132A95ABAA *PFWF164A96ABAA *PFWF201A97ABAA *PFWF071A93ABA for 3 Pass Cast Iron for 3 Pass Cast Iron for 3 Pass Cast Iron for 3 Pass Cast Iron Burner Model for 3 Pass Cast Iron HX, 4 Sections HX, 5 Sections...
  • Page 40 ELECTRODE SETTING BURNER INSTALLATION IMPORTANT: These dimensions MUST be observed A. Screw the four (4) M8 x 1.25 double end threaded and verifi ed. (Figure 36) studs in the four equally spaced threaded holes located in the boiler door. Screw the short end of the 5/32”...
  • Page 41 Figure 39b Model BF3 and BF5 1. Mounting Flange 2. Mounting Gasket 3. Burner Access Hole 4. M8 x 1.25 Double End Threaded Studs, included with boiler hardware Figure 39 WET BASED CHAMBER APPLICATIONS The electrical connection between the boiler and the burner is made using a 7-pin plug.
  • Page 42 To install the by-pass plug: (Figure 40) SINGLE LINE (GRAVITY FEED SYSTEM) 1) Remove the return plug (7) 2) Install the by-pass plug (4) using the 2.5 mm hex- A. The burner is shipped confi gured for use in single agonal key line applications.
  • Page 43 ▲ ▲ ▲ ▲ CAUTION WARNING PIPE DOPE AND TEFLON TAPES ARE NOT TO The vacuum should not exceed 11.44 inches of mer- BE USED ON ANY DIRECT OIL CONNECTION TO cury. THE FUEL PUMP. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY, NOTE: An external, appropriately listed and certi- DEATH, OR PROPERTY DAMAGE.

  • Page 44: Optional Manual Reset Water Temperature Limit Installation

    Steps to remove the existing auto-reset water tempe- 3.10 Installation Instructions for repla- rature limit switch. cing the Factory Installed Automatic- 1. Open the control panel and locate the existing reset Water Temperature Limit with the auto-reset water temperature limit. See Figures 45 Optional Manual Reset Water Tempera- and 46.
  • Page 45 3. Remove the wires from the existing auto-reset 6. Remove the cable ties to isolate and remove the water temperature limit. See Figure 48. capillary tube of the existing auto-reset water tempe- rature limit switch. See Figure 51. Figure 48 Figure 51 4.
  • Page 46 8. Locate the capillary tube of the existing auto- 2. In a similar manner, remove the locking nut from reset water temperature limit and remove it from the the new manual reset water temperature limit. See strain relief clamp. See Figure 53. Figure 55.
  • Page 47 4. Center the reset button in the hole and secure 6. Attach the wires removed earlier from the auto- with a locking nut. Use needle nose pliers. See reset water temperature limit to the new manual Figure 57. water temperature limit. See Figure 59. Figure 57 5.
  • Page 48 8. Place the bulb of the new manual reset water 10. Tighten the strain relief cable clamp with a temperature limit along with the existing adjustable screwdriver. See Figure 63. supply water thermostat and thermometer gauge bulbs in the boiler temperature well and secure with a spring clip.
  • Page 49 ▲ Using 18 gauge control wire, connect control wiring WARNING to thermostat or other external as required. Consult the National Electrical Code, ANSI/NFPA 70-2002, for TO PREVENT INJURY OR DEATH DUE TO ELECTRICAL SHOCK OR CONTACT WITH guidelines for proper wiring methods and materials for MOVING PARTS, LOCK UNIT DISCONNECT control circuits.

  • Page 50: Electrical Connections

    3.11 Electrical Connections CONNECTION TO ELECTRICAL GRID The boiler must be connected to single-phase, 120 Important: All aspects of the installation of this boiler, Volt-60 Hz electric service. including electrical materials and methods of supplying electrical power must comply with all local codes and the following national standards: 1) NFPA 70 (most recent edition) - National Electrical Code CONTROL BOX ACCESS...

  • Page 51: Supply Water Thermostat (Swt) Settings Above 180°F

    2. Look on the back of the knob and fi nd the 3.12 Supply Water Thermostat metal rotation stop in one of the numbered (SWT) Settings Above 180°F positions (see Figure 66). This metal stop The adjustable SWT knob includes a factory instal- should have been factory set to position 1 led rotation stop that prevents supply water tempe- or 7.

  • Page 52: Technical Data

    4.0 Technical Data 4.1 Electrical Diagrams 18-CG03D1-4...

  • Page 53: Schematic Diagram

    4.2 Schematic Diagram 18-CG03D1-4...

  • Page 54: Field Wiring Diagrams

    4.3 Field Wiring Diagrams Option 1 - Factory Jumpers in Place System Configuration 1. Continuous Pump Operation 2. Burner Cycles With Supply Water Thermostat Circ Pump 120 VAC Power Setup (Field Supplied) (Field Wiring) 1. No changes needed L1 N (LV) (HV) 13 14 15 16 17 18...
  • Page 55 Option 3 - Field Installed Room System Configuration Thermostat, Orange J2 jumper 1. Pump Runs on Call from Room Thermostat OR if Water Temperature is Above Supply Water removed Thermostat setting 2. Burner Cycles with Supply Water Thermostat External Setup Limits (e.g., LWCO) 120 VAC Power...
  • Page 56 Option 5 - Field Installed Room System Configuration Thermostat, Orange J2 jumper removed, 1. Pump Runs on Call from Room Thermostat OR Yellow J5 jumper removed if Water Temperature is Above Supply Water Thermostat setting External 2. Burner Cycles with Supply Water Thermostat during Call from Room Thermostat.
  • Page 57 Boiler Reset Option - Field Wiring Boiler Reset Configuration for Field Supplied Boiler Temperature NOTE: This Boiler Reset option may be Reset Controls (to Decrease Boiler Water used in combination with any of the other Temperature with Increasing Outdoor system configuration options and jumper arrangements shown in this document.

  • Page 58: Start-Up And Adjustment

    Visually inspect the venting system for proper 4.4 Start-Up and Adjustment size, horizontal pitch and vent termination, and verify the vent system is not blocked or ▲ ▲ WARNING restricted, does not leak, has no corrosion and any other defi ciency which could cause and CARBON MONOXIDE POISONING HAZARD unsafe condition.
  • Page 59 BURNER MODELS BAYRAF03ABURNA, BAYRA- F05ABURNA, BAYRAF10ABURNA: 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.
  • Page 60 BURNER MODELS BAYRBF03ABURNA and BAYRBF05ABURNA: SETTING THE AIR ADJUSTMENT PLATE The initial air damper setting is made by turning screw (2) until the top edge of the air damper (3) is alligned with the number according to the burner setup chart. Further adjustments can be made with the burner cover in place by removing plastic plug on the top right hand side of the cover.
  • Page 61 ▲ WARNING Control and Safety Switch Adjustment CARBON MONOXIDE POISONING HAZARD Limit Switch Check Out Failure to follow the steps outlined below for each The limit switch is a safety device designed to shut appliance connected to the venting system being off the burner should the boiler become overheated.
  • Page 62 BURNER START-UP FORM* Burner S/N or Appliance:: Model: Installer name: Installation Company: date: Address: Phone: Fax: Owner Name: Address: E-mail: Phone: Burner Start-up Info (GAS) Burner Start-up Info (OIL) Nozzle Info: Gas Supply Pressure: Pump Pump Pressure: Pressure: Turbulator Air Setting: setting: Air Setting: Head Setting:...

  • Page 63: Appendix

    6.0 Appendix A Insulated Direct Vent System for Oil Burning Appliances INSTALLATION AND MAINTENANCE INSTRUCTIONS PRODUCT: Flexible Insulated Direct Vent System for oil burning appliances. COMPONENT LIST: Part No. Description BAYDVK10ARELLAA Direct Vent Kit for BF Oil Burner - 10 Ft Long (Does not include vent terminal)* BAYDVK20ARELLAA Direct Vent Kit for BF Oil Burner - 20 Ft Long...
  • Page 64 INSTALLATION CONSIDERATIONS (Illustration #1) 1) The vent pipe bend radius is 12". 2) Place metal strapping every 36" to support vent pipe and prevent it from sagging. 3) Maximum wall thickness is 14". Contact the manufacturer for recommendations in case of thicker wall. 4) This system is not designed for common venting.
  • Page 65 JOINT ASSEMBLY (Illustration #2 & #3) 1) Loosen the gear clamp attached to the adapter sleeve. 2) Pull the corrugated inner pipe out of the vent pipe for easy access to insert the adapter. 3) Apply sealant around the corrugated end of the adapter. 4) Align the flat seams at the end of both corrugated pipes and insert the adapter into the vent pipe.
  • Page 66 CONNECTIONS TO TERMINAL (Illustration #6 & #7) 1) Slide the terminal inner section over the vent pipe. 2) Connect the terminal adapter to the vent pipe as per joint assembly. 3) Apply a bead of sealant around the terminal flue collar. 4) Slide the appliance adapter pipe over the flue collar.
  • Page 67 18-CG03D1-4...
  • Page 68 Flex-L, International and Z-Flex. ® Literature Order Number 18-CG03D1-3 P.I. File Number 18-CG03D1-3 American Standard Inc. Supersedes 6200 Troup Highway Stocking Location P.I. 08/02 Tyler, TX 75707 For more information contact Since the manufacturer has a policy of continuous product and product data improvement, it reserves the your local dealer (distributor) right to change design and specifi...

This manual is also suitable for:

Pfwf099a94abaPfwf132a95abaPfwf164a96abaPfwf201a97abaPfwf242a98abaPfwf286a99aba

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