American Standard PFWF071A93ABA Installation Manual Download

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Oil Fired Water Boiler
with Three Pass Cast Iron Heat Exchanger

INSTALLATION GUIDE

*PFWF071A93ABA
*PFWF099A94ABA
*PFWF132A95ABA
*PFWF164A96ABA

* May be “A” or “T”

IMPORTANT —

This Document is

customer property

and is to remain with this unit. Please

return to service information pack upon completion of work.

ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES

18-CG03D1-4

*PFWF201A97ABA
*PFWF242A98ABA
*PFWF286A99ABA

Summary of Contents for PFWF071A93ABA

Page 1: ...2A95ABA PFWF164A96ABA May be A or T IMPORTANT This Document is customer property and is to remain with this unit Please return to service information pack upon completion of work ALL phases of this in...

Page 2: ...TERPRETATION OF THIS INFORMATION NOR CAN IT ASSUME ANY LIABILITY IN CON NECTION WITH ITS USE WARNING ELECTRICAL HAZARD DISCONNECT POWER BEFORE INSTALLING OR SERVICING FAILURE TO FOLLOW THIS WARNING CO...

Page 3: ...ATION IN MANU FACTURED MOBILE HOUSING TRAILERS OR RECREATIONAL VEHICLES FAILURE TO FOLLOW THIS WARNING COULD RESULT IN SERIOUS INJURY DEATH OR PROPERTY DAMAGE WARNING WATER DAMAGE HAZARD DO NOT USE TH...

Page 4: ...tion 8 Alwaysinstalltheboilertooperatewithintheboiler s temperatureoperatingrangeandinstallthespecified ASME approved pressure relief valve for the boiler See the Service Facts that ship with the boil...

Page 5: ...crating Boiler 12 3 4 Leveling Boiler 12 3 5 Water Connections and Piping Diagrams 12 3 6 Combustion Air and Ventilation 18 3 7 Flue Chimney Vent Connector 20 3 8 Boiler Swing Door Conversion 27 3 9 O...

Page 6: ...xchanger b Factory installed High Temperature Limit Switch with auto reset c Factory installed Supply Water Thermostat d Factory installed On Off service switch e Factory installed Pressure Temperatur...

Page 7: ...ello Non Direct Vent 40 Series 2 3 4 BAYRAF03ABURNA BAYRAF03ABURNA BAYRAF05ABURNA Riello Direct Vent 40 Series 2 3 4 BAYRBF03ABURNA BAYRBF03ABURNA BAYRBF05ABURNA Crated Dimensions inches H x W x D 40...

Page 8: ...embled Burner cord pre wired with 7 pin plug that connects to boiler 4 BAYRAF10 ships with a factory installed nozzle for use with PFWF242A An additional nozzle which requires field installation is in...

Page 9: ...OR INSTALLATION ON COMBUSTIBLE FLOORING DO NOT INSTALL ON CARPET a Location Considerations Before the boiler is moved into place be sure to consider the following requirements 1 Proximity to the chimn...

Page 10: ...Right Side 6 24 a Left Side 6 6 a Front 18 30 b Back 6 24 b The minimum clearances from boiler casing surfaces to combustible materials are a Leave at least 24 on one side of the boiler and 6 on the...

Page 11: ...ler first see sec tion 3 3 and use an appliance dolly capable of handling the boiler weight to move the boiler to the selected location 3 If required the boiler jacket may be removed to simplify handl...

Page 12: ...ION LEADS TO CORRO SION AND PREMATURE BOILER FAILURE THE BOILER STANDARD LIMITED WARRANTY DOES NOT COVER OXYGEN CONTAMINATION OF BOILER OR SCALE DEPOSITS CAUSED BY MAKE UP WATER ADDED TO THE SYSTEM FA...

Page 13: ...ESULT IN SERIOUS INJURY DEATH OR PROPERTY DAMAGE Head Loss vs Flow Chart for All PFWF Models 7 A 3 4 pipe must be routed from the outlet of the pressure relief valve to the nearest suitable drain This...

Page 14: ...Return water temperature must be above 110 O F Typical System Piping Diagram Single Zone System High Temperature with Low Mass Heat Emitters 1 1 NOTES Locate the circulator inlet close to the connecti...

Page 15: ...ass Heat Emitters Return Water Temperature Sensor Supply Water Temperature Sensor Heat Emitter Return water temperature must be above 110 O F NOTES Protects boiler from too low return water temperatur...

Page 16: ...ture with High or Low Mass Heat Emitters Return Water Temperature Sensor Supply Water Temperature Sensor Return water temperature must be above 110 O F Heat Emitter 1 2 1 2 NOTES Protects boiler from...

Page 17: ...Emitters Circulator Pump Circulator Pump Return Water Temperature Sensor Supply Water Temperature Sensor Return water temperature must be above 110 O F Heat Emitter 2 1 2 1 3 3 NOTES Protects boiler...

Page 18: ...an ger and or the venting system Often household chemicals contain chloride bearing compounds There are many compounds representative of this classifica tion of chemicals A few common examples are Cle...

Page 19: ...and penetrations wherein infiltration and air exchange with the outdoors is very limited 0 35 air changes per hour or less provision must be made to provide sufficient air for combustion The followin...

Page 20: ...onfined space of a building with traditional construction loose typi cally have enough infiltration air for combustion and ventilation 7 Outdoor air may also be provided by combining the following PFW...

Page 21: ...scharge termi nation Excessive corrosion at the cleanout port or at the chimney connector entrance into the chimney Structural debris i e mortar or tile liner flakes in base of the flue way A qualifie...

Page 22: ...from the boiler to the chimney Long horizontal sections of the venting system must be supported at least every five 5 feet with metal straps to prevent sagging of the vent piping Secure all joints in...

Page 23: ...tilated air space 5 3 A Equal the required clearance with no protection B Equals the reduced clearance permitted in accordance with the preceeding clearance chart C The protection applied to the const...

Page 24: ...gaseous state if the internal chimney wall temperature is above the dew point or B Condense water vapor on the chimney walls if they are chilled below the dew point Condensing will always occur on ch...

Page 25: ...also be used B Use adapter BAYDVK10AADPTA to connect to the BAYRBF burner air intake C Always keep intake air run to the minumum D Maximum intake air run for 4 inch diameter flexible or rigid type of...

Page 26: ...Terminal Standard Combination Fresh Air Intake And Flue Vent BAYVTR10AFAFVA Vent Terminal 18 Riser Combination Fresh Air Intake And Flue Vent BAYVTR20AFAFVA Vent Terminal 36 Riser Combination Fresh Ai...

Page 27: ...or to open from the right use the follow ing instructions to convert the door 1 Remove upper and lower front access panels Each panel is attached to the boiler with 4 pins one in each corner Pull pane...

Page 28: ...se to tighten 8 Remove the threaded rods with hex nuts from the left side of the boiler door frame Install hinges as illustrated Figure 23 Figure 24 6 Remove the upper and lower hinges To remove rotat...

Page 29: ...18 CG03D1 4 29 9 Set the swing door on the hinges while inserting hinge pins saved from step 3 10 Replace cotter pins Proceed with installing burner on swing door Figure 27 Figure 28...

Page 30: ...he actual installation of the burner Combustion results must be veri fied using proper combustion test equipment The manufacturer of the burner and boiler will not be responsible for the improper inst...

Page 31: ...z 10 15 ABSORBED ELECTRICAL POWER 155 Watts 175 Watts 230 Watts MOTOR rated 3250 rpm Run Current 2 2 AMP 3250 rpm Run Current 2 2 AMP 3250 rpm Run Current 2 2 AMP CAPACITOR 12 5 Microfarads 12 5 Micro...

Page 32: ...e veri fied using proper combustion test equipment The manufacturer of the burner and boiler will not be responsible for the improper installation or set up of the appliance It is mandatory that a com...

Page 33: ...0Hz 10 15 ABSORBED ELECTRICAL POWER 192 Watts 204 Watts MOTOR rated 3250 rpm Run Current 2 2 AMP 3250 rpm Run Current 2 2 AMP CAPACITOR 12 5 Microfarads 260V 12 5 Microfarads 260V PUMP PRESSURE 100 to...

Page 34: ...5 Motor 6 Air Adjustment and Shutter 7 Electronic Air Shutter Assembly 8 Combustion Head 9 Flange 10 Supply Fuel Line Port 11 Pump Valve Coil 12 Vacuum Gauge Port 13 Pressure Gauge and Bleeder Port 14...

Page 35: ...sure Regulator 5 24V Switching Relay 6 Air Adjustment 7 Capacitor 8 Combustion Head 9 Welded Flange 10 Wire Harness 11 Turbolator Adjustment Screw 12 Coil 13 Bleeder and Pressure Gauge Port 14 Return...

Page 36: ...F3 F5 F10 SERIES OIL BURNER EQUIPPED WITH AN ELECTRONIC AIR SHUTTER INTERNAL FACTORY WIRING INTERNAL FACTORY WIRING M 1 AUX 2 3 4 5 6 7 8 L N 12 11 10 9 C A D C D A B AUX T T D7871 EARTH GROUND MOTOR...

Page 37: ...PRIMARY CONTROL 1 and then unplug by carefully pulling it back and then upward 2 Remove the AIR TUBE COVER PLATE 5 by loosening the two retaining SCREWS 4 See Figures 33 and 34 Two screws for Model BF...

Page 38: ...e combustion chamber it is recommended that the air tube and flange be sealed 4 Unit model PFWF071 and PFWF099 BAYRAF03ABURNA burner with 6 slots reverse flow turbulator disk 5 Burners tested under si...

Page 39: ...p of end cone to flange 3 Due to positive pressure in the combustion chamber it is recommended that the air tube and flange be sealed 4 Unit model PFWF071 and PFWF099 BAYRBF03ABURNA burner with 6 slot...

Page 40: ...gasket onto the studs and seat against the door See Figures 38B 39A item 2 C The burner may now be attached to the boiler by inserting the air tube through the burner access hole 8 and into the applia...

Page 41: ...o female NPT to adapt oil lines to burner pipe connectors All pump port threads are British Parallel Thread design NOTE Direct connection of NPT threads to the pump will damage the pump body Model BF3...

Page 42: ...xagonal 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 oper ating on a two line system supply and...

Page 43: ...its proper location start the burner 6 When the solenoid valve is engaged ap proximately 10 seconds after starting remove the air tube cover and shine a light source on the photocell allowing it to se...

Page 44: ...IS INSTALLATION FAILURE TO FOLLOW THE SAFETY WARNING EXACTLY COULD RESULT IN SERIOUS INJURY DEATH OR PROPERTY DAMAGE Figure 45 Figure 46 Figure 47 Reset Button Cover Capillary Tube Sensing Bulb Manual...

Page 45: ...n relief cable clamp with a screwdriver See Figure 50 6 Remove the cable ties to isolate and remove the capillary tube of the existing auto reset water tempe rature limit switch See Figure 51 Figure 5...

Page 46: ...W MANUAL RESET WATER TEMPERATURE LIMIT 1 Remove the cover from the reset button on the new manual reset water temperature limit switch by turning counter clockwise See Figure 54 2 In a similar manner...

Page 47: ...et button cover on the new manual reset water temperature limit switch See Figure 58 6 Attach the wires removed earlier from the auto reset water temperature limit to the new manual water temperature...

Page 48: ...63 Figure 64 9 Route the capillary tube of the manual reset water temperature limit with the other capillary tubes dress neatly and secure with new cable ties See Figure 62 10 Tighten the strain reli...

Page 49: ...l installation codes A disconnect switch equipped with overcurrent protec tion e g a time delay type fuse or inverse time circuit breaker should be installed in the service line for shutting down and...

Page 50: ...ectrical 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 US 2 CSA 22 1...

Page 51: ...Remove the knob from the adjustable SWT by pulling the knob directly outward away from the boiler Figure 66 Figure 67 Figure 68 2 Look on the back of the knob and find the metal rotation stop in one o...

Page 52: ...18 CG03D1 4 52 4 0 Technical Data 4 1 Electrical Diagrams BK G BL GY BR...

Page 53: ...18 CG03D1 4 53 4 2 Schematic Diagram...

Page 54: ...cles with Supply Water Thermostat when Call from Room Thermostat is present Burner Operation is Prevented when Room Thermostat is Satisfied Setup 1 Remove Yellow J5 jumper External Limits where requir...

Page 55: ...15 16 17 18 HV LV T T 19 20 L N POWER 1 2 3 LWCO 5 6 J2 ORANGE 7 8 L N PUMP 9 10 11 J4 BLUE 21 22 J5 YELLOW 23 24 System Configuration 1 Pump Controlled by Room Thermostat 2 Burner Cycles with Supply...

Page 56: ...14 15 16 17 18 HV LV T T 19 20 L N POWER 1 2 3 LWCO 5 6 J2 ORANGE 7 8 L N PUMP 9 10 11 J4 BLUE 21 22 J5 YELLOW 23 24 System Configuration 1 Pump Runs off Room Thermostat 2 Burner Cycles with Supply Wa...

Page 57: ...operation based on reset control curve 4 Adjust supply water thermostat SWT to its maximum setting Boiler Reset Option Field Wiring for Field Supplied Boiler Temperature Reset Controls to Decrease Boi...

Page 58: ...ting system for proper size horizontal pitch and vent termination and verify the vent system is not blocked or restricted does not leak has no corrosion and any other deficiency which could cause and...

Page 59: ...e air plate screw 3 move air plate 4 by using the air gate adjust arm After adjustments are made retighten screws 3 5 The final position of the air adjustment plate will vary on each installation Use...

Page 60: ...p 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...

Page 61: ...ng any of the above tests the venting system must be corrected in accordance with the National Fuel Gas Code ANSI Z221 1 NFPA 54 and or CAN CGA B149 Installation Codes 8 After it has been determined t...

Page 62: ...O2 CO O2 Smoke density Bacharach Single Line Two Lines Turbulator setting Dratt breech Burner Start up Info GAS Gas Supply Pressure Pump Pressure Air Setting Draft Over fire CO2 CO O2 Manifold pressur...

Page 63: ...t Vent Kit for BF Oil Burner 20 Ft Long Does not include vent terminal BAYDVK10AADPTAA Adapter Combustion Air Intake 3 to 4 BF Oil Burner BAYVKS10ATUBEAA Vent Pipe Sealant Direct Vent Oil Burner 10 OZ...

Page 64: ...g 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...

Page 65: ...try again as per Step 4 5 Seal around edge of vent pipe inner pipe 6 Tighten the gear clamp to complete the connection 7 If the vent requires cutting to length a fine toothed hacksaw can be used Remov...

Page 66: ...6 Seal the seam in the adapter with sealant 7 Slide the inner section over the outer section and secure by tightening the gear clamp 8 Stretch the air intake flex to the desired length and slide over...

Page 67: ...18 CG03D1 4 67...

Page 68: ...s a policy of continuous product and product data improvement it reserves the right to change design and specifications without notice American Standard Inc 6200 Troup Highway Tyler TX 75707 For more...

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