Central Boiler FORGE 1500 Owner'S Manual Download

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FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL

CENTRAL BOILER ONLINE RESOURCES

Enter CentralBoiler.com in your browser or scan the code using any QR code reader app on your smartphone to access Central

Boiler's library of information to help with installation, operation and maintenance of your Central Boiler outdoor furnace.

Detailed Furnace Installation Variations

- http://www.CentralBoiler.com - go to Explore > Furnace Installation

View and/or download PDFs to assist in installation of your outdoor furnace. Information and examples

regarding pumps, foundations, chimneys and support structures, ThermoPEX piping, and example configurations

for a variety of heating configurations.

Product Service Videos

- http://www.CentralBoiler.com - go to Explore > Videos

Push-fit Fittings

Central Boiler's push-fit fittings make configuring and connecting your

heating system easy and quick.

Performing a Water Test

Testing and maintaining the water in your system is critical for the

operation and longevity of your heating system.

INSTALLATIONS IN MASSACHUSETTS:

All installation components must be products approved in the Commonwealth of Massachusetts by the Gas and Plumbing Board.

The maximum run of tubing from the water heater to a fan coil is 50 linear feet.

Persons operating this hydronic heater are responsible for operation of the hydronic heater so as not to cause a condition of air pollution as

defined in 310 CMR 7.01(1).

Videos to supplement the Owner's Manual are available at

www.youtube.com/centralboilerinc

Watch tips on initial startup, testing system water and more.

Summary of Contents for FORGE 1500

Page 1: ...ors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch Immediately call your gas supplier Follo...

Page 2: ...9 91 Pa Maximum draft is marked on nameplate Forge 1500 Water Capacity 150 gal Weight 1 750 lbs Forge 3500 Water Capacity 210 gal Weight 2 150 lbs French Owner s Manual and decal set available upon re...

Page 3: ...g Instructions 14 FireStar Combustion Controller 14 Firebox Door Opening Procedure 14 Maintaining the Ash Bed 15 Cold Start Firing 15 Adding Heat Load 19 Loading Frequency 19 About Clinkers 24 Dump to...

Page 4: ...rvice Videos http www CentralBoiler com go to Explore Videos Push fit Fittings Central Boiler s push fit fittings make configuring and connecting your heating system easy and quick Performing a Water...

Page 5: ...auseminorpersonal injury or property damage if ignored NOTE Indicates supplementary information worthy of particular attention relating to installation operation or maintenance of the outdoor furnace...

Page 6: ...t refers to an instance with the firebox door or ash door being opened when combustible gases are present or when breaking up a burning coal bed Under Air The main combustion air supply Under air is t...

Page 7: ...front portion of the slab and under the area of the ground used for walking CAUTION Do not use any combustible materials for the foundation NOTE Theinstallationsurfaceorfoundationmustbenoncombustible...

Page 8: ...Swing Check Valve 3 4 2 556 Power Supply Cord 4 1330 MPT to PEX 3 4 x 1 4 5926 Stainless Steel Clamp Crimp Ring 1 2 6054 Temperature Gauge 1 6593 Grounding Rod Kit 1 5000018 Nipple 3 4 x 3 1 534 Nipp...

Page 9: ...ten all hardware securely NOTE A hole for the ground terminal has been pre punched in the outdoor furnace base near the pumps Furnace Installation Connecting toYour Existing System A common installati...

Page 10: ...comply with all applicable codes and regulations NOTE Any electrical installation should be done by a qualified installer in accordance with applicable codes NOTE A certified electrician must do the e...

Page 11: ...s and cardboard 3 LOADING FUEL For a more efficient burn pay careful attention to loading times and amounts Follow the manufacturer s written instructions for recommended loading times and amounts 4 S...

Page 12: ...here are dry conditions or where there is combustible material near the unit unless the installation of a spark arrester is prohibited by local requirements Use common sense to avoid potential fires i...

Page 13: ...on the vent opening Do not force the cap down or try to seal it tightly onto theventpipe Donotextendorrestricttheventpipeoropening DO NOT ALLOWTHE OUTDOOR FURNACETO BE PRESSURIZED Be sure the outdoor...

Page 14: ...tial fire NOTE The use of wood in this outdoor furnace except for the purpose of igniting the coal is prohibited by law NOTE The sight gauge valve should always be closed except when checking water le...

Page 15: ...size loading techniques and controller settings These can be helpful when fine tuning your outdoor furnace to achieve the most efficient and cleanest possible burns Perform the recommended preventativ...

Page 16: ...ains consistently similar characteristics even between different mines The swell factor the property of coal to swell and bind to other pieces when heated is almost nonexistent so even when glowing re...

Page 17: ...its Btu moisture sulfur ash and volatile content per pound Because of this certain additional precautions need to be taken when burning bituminous The higher volatile and sulfur content gives bitumin...

Page 18: ...will illuminate violet 30 seconds into the purge cycle After approximately one minute once the purge cycle is complete these three LEDs will turn green 5 If there is no smoke or only small wisps of s...

Page 19: ...r after an extended period of down time Just like burning wood burning coal can be more of an art than a science You may need to vary techniques to achieve best results Over time you will learn the pr...

Page 20: ...tend to the fire 6 Gradually place pieces of wood on top of the burning kindling starting with very small pieces increasing the size of the kindling as the fire grows Once a large hot fire is establi...

Page 21: ...nsiderable amount of moisture from condensation will collectinsidethefireboxandmaydripout Thisisnormalandthemoisturewillevaporate after the first couple of fuel loads NOTE During initial start up it i...

Page 22: ...ereleased which could result in heavy smoke billowing out the firebox door If this happens immediately shut the firebox door and wait for the smoke to die down by watching the chimney 9 After the coal...

Page 23: ...setpoint 2 Turn on the pump s then start a heat load draw in the system by turning up the thermostat in the house Monitor the outdoor furnace for one hour or until another cycle occurs i e outdoor fur...

Page 24: ...s 3 Observe the coal bed to make sure all the coals are glowing Dark spots in the coal bed indicate a blockage of air that needs to be cleared Use the rake to gently stir the area and break up the ash...

Page 25: ...cedure open the firebox door 2 Observe the coal bed Refer to the Bituminous Loading Methods section for the suggested technique to use for loading bituminous dependant on the condition of the coal bed...

Page 26: ...ing coals New bituminous load The hot coals are pushed toward the back of the firebox to form a small hill and a valley is created from the hill to the front of the firebox make sure the valley still...

Page 27: ...l containing small fines or to burn surplus coal fines It takes advantage of the swell factor that is common with many types of bituminous coal For this method the coal bed is either raked flat or wit...

Page 28: ...ituminous load This method works very well with bituminous especially if the Reset function is utilized Similar to the Hill and Valley method the newly added bituminous is added on the side opposite o...

Page 29: ...le If the clinker is flat it can sometimes be broken up into smaller pieces using the rake and then be sifted through the shaker grates 2 To remove larger clinkers allow the outdoor furnace to burn th...

Page 30: ...forward shake it quickly a couple of times and then return the grates to the horizontal closed position 8 Wait for at least a minute to allow the ash and dust to settle 9 Using the Firebox Door Openi...

Page 31: ...g lid Make sure all ash has been removed Use the provided tools to stir and break apart any clumped ash CAUTION Remove as much ash as possible Ash can trap moisture which can greatly increase the chan...

Page 32: ...very six months thereafter F Frequency will vary depending on heat load requirements and type of coal used E Refer to Testing Treated Water in the Outdoor Furnace A A A C C C D Inspect and clean the c...

Page 33: ...schedule are intended to serve as a guideline Actual intervals between inspections and maintenance may vary depending on a number of factors including your heat load requirements type of coal used an...

Page 34: ...ean and in good condition MAINTENANCE SECTIONS Refer to the Preventive Maintenance Schedule for the recommended intervals with which to perform these maintenance items 3 1 Water Level Open the sight g...

Page 35: ...on as a reference push a cleaning rod or similar tool back and forth through the ash in the bottom of the firebox in the locations indicated by the lines Feel for any clinkers work them to the top of...

Page 36: ...or soot have accumulated allow the outdoor furnace to cool down and then remove with a brush 3 7 Ash Collection Chamber NOTE The properties of the ash removed can help to identify how frequently the g...

Page 37: ...quickly scoop out the ash and store in a metal container with a tight fitting lid Make sure all ash has been removed Use the provided tools to stir and break apart any clumped ash 2016 Central Boiler...

Page 38: ...ause and correct it as soon as possible Refer to Corrosion is Present in the Troubleshooting section 3 A thin tar like creosote layer may form on the firebox walls and migrate toward the bottom of the...

Page 39: ...ombustion fan bearings using the following procedure 4 Remove the bolts securing the combustion fan and remove the combustion fan 5 Hold fan so the oil locations are upright then apply 10 drops of SAE...

Page 40: ...e the air elbow Clamp Air Elbow Air Tube 5 Inspect the elbow and clean out any build up or blockage NOTE A small amount of material in the elbow is normal and is not an indication of improper operatio...

Page 41: ...appropriate personal protective gear e g protective gloves clothes dust mask etc when cleaning ash from the firebox and the ash collection chamber CAUTION Clear the entire area surrounding the outdoor...

Page 42: ...f the furnace then use a small shovel to remove all of the ash and deposits from the ash collection chamber Take care not to push any debris into the under air outlet NOTE It is extremely important to...

Page 43: ...he area inside the firebox Pay special attention to scraping the front corners Scrape any crusty deposits off the firebox walls Scrape the shaker grates and make sure the shaker grate slots are free o...

Page 44: ...ing a new test kit The pH test strips and Permanganate Reagent each have a varying shelf life that can affect their accuracy Test kits should be stored in a dry area at room temperature to obtain maxi...

Page 45: ...clean container 2 Dip the pH test strip from the test kit in the water sample Shake excess water off the test strip Compare the color of the test strip to the chart provided to determine pH level 3 If...

Page 46: ...e valve when finished The water in the sight gauge valve and tube will drain when the valve is closed CAUTION The water in the sight gauge may be hot Use caution when obtaining a sample 2 If no antifr...

Page 47: ...but 15 to 30 drops is acceptable One drop of permanganate reagent equals approximately 100 ppm SYSTEM MAINTENANCE The pH and nitrite levels of the water once treated should remain stable as long as w...

Page 48: ...tor Plus level has not been maintained and corrosion is present in the water jacket The water jacket should be thoroughly flushed and the system refilled with the proper amount of Corrosion Inhibitor...

Page 49: ...rnace following the procedure in Water Quality and Maintenance Start the pump s and bring the water temperature up to operating temperature 185 F for two hours with the system circulating to thoroughl...

Page 50: ...oughly cool and completely clean out the firebox and ash collection chamber before servicing any item on the outdoor furnace Always follow the Firebox Door Opening Procedure to reduce the possibility...

Page 51: ...roove Any residue left in the groove will interfere with the new rope seal 3 Apply a liberal amount of silicone sealant into the entire firebox door seal groove 4 Starting at the center of the hinge s...

Page 52: ...power to the furnace 2 Open the ash removal door 3 Use a flat shovel and hoe to remove all the ash from the ash collection chamber Be careful not to push ash or debris into the under air outlet Remove...

Page 53: ...k off any accumulated soot from the thermocouple On the rare occasion the thermocouple needs replacement follow these steps 1 Disconnect power to the outdoor furnace Do not proceed without testing tha...

Page 54: ...will shut down the furnace if the water temperature has been too low for too long Determine the cause of the water temperature being too low 11 Alarm condition Refer to FireStar Operating Instruction...

Page 55: ...s clean and unobstructed Objects like buildings and trees in close proximity or nearby terrain e g hills valleys etc can adversely affect air flow in the chimney Adding chimney sections may overcome t...

Page 56: ...The opening in the shaker grates need to be free of obstructions so combustion air can flow properly Check for clinkers and remove them Refer to the About Clinkers section for more information C BUILD...

Page 57: ...ture the first time will take a considerable amount of time and wood once warm wood consumption will be reduced if the concrete slab and building are insulated properly 14 Heat load too large Re evalu...

Page 58: ...er is not circulating Check to make sure the pump is operating and water is circulating continuously through the supply and return lines to keep water temperature uniform in the outdoor furnace 5 Circ...

Page 59: ...ter or cold outside temperatures will require increased coal consumption see Hydronic Installations section Bringing a cold concrete slab up to temperature the first time will take a considerable amou...

Page 60: ...ough temperatures to dry the firebox and corrosion can occur Re evaluate the system and match heat load to the outdoor furnace NOTE To reduce condensation in the firebox it is NOT recommended to set t...

Page 61: ...16 1 5 8 62 41 Chestnut 1 5 8 13 16 41 21 Pea 13 16 9 16 21 14 Buckwheat 9 16 5 16 14 8 Rice 5 16 3 16 8 5 Barley 3 16 3 32 5 2 Bituminous Sieve Size inches Sieve Size mm THROUGH RETAINED THROUGH RETA...

Page 62: ...se d clarer Si un feu de chemin e survient ou imm diatement apr s avoir teint le feu verrouillez la porte du foyer Ne laissez PAS la chaudi re sans surveillance lorsque la porte du foyer ou celle d e...

Page 63: ...59 FORGE OUTDOOR COAL FURNACE OWNER S MANUAL WIRING DIAGRAM...

Page 64: ...Printed in U S A 2017 Central Boiler p n 9000578 REV A 18 DEC 2017...

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