Force FORCE02E Installation, Operating And Service Instructions Download | Manualshive

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FORCE E

Installation, Operating & Service Manual

109444-03 - 12/19

Key No.

Description

Part Number [Quantity]

FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E

4A

Hydrostat 3200 LWCO/High Limit

109952-01 [1]

4B

Honeywell S8610M EI Module

109945-01 [1]

15

Service Parts

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Summary of Contents for FORCE02E

Page 1: ...ge Specifications 3 Pre installation 4 Removing Existing Boiler 5 Clearances 5 Venting 7 Water Piping 10 Gas Piping 13 Electrical 14 System Start Up and Checkout 17 Operation 22 Before Leaving Jobsite...

Page 2: ...ate injury WARNING Indicates a hazardous situation that if not avoided could result in death or serious injury DANGER Explosion Hazard DO NOT store or use gasoline or other flammable vapors or liquids...

Page 3: ...Supply NPT Return NPT Vent in Gas NPT Relief Valve NPT Drain NPT Maximum Allowable Working Pressure PSI FORCE02E 2 32 14 40 1 1 4 1 1 4 4 1 2 3 4 3 4 50 FORCE03E 3 32 14 40 1 1 4 1 1 4 4 1 2 3 4 3 4 5...

Page 4: ...combustion and dilution air I Do not install boiler where gasoline or other flammable vapors or liquids are stored Avoid areas near chemical products containing chlorine chloride based salts chloro f...

Page 5: ...Instructions Adjust thermo stat so appliance will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle...

Page 6: ...ector Otherwise follow vent connector manufacturer s recommended clearances Additional height required to maintain 6 clearance from all vent connector components Vent damper may be installed in vertic...

Page 7: ...yhavingjurisdiction orStandard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances NFPA 211 Masonry chimney must be lined with listed clay flue lining or listed chimney lining system 3 Sin...

Page 8: ...with head room available and required clearancefromadjacentcombustiblebuilding structure Ventpipeshouldbeinstalledabove bottom of chimney to prevent blockage 6 Slope vent pipe upward from draft diver...

Page 9: ...Gas Vent Roof Slope Heights Roof Slope ft Flat to 6 12 1 0 Over 6 12 to 7 12 1 25 Over 7 12 to 8 12 1 5 Over 8 12 to 9 12 2 0 Over 9 12 to 10 12 2 5 Over 10 12 to 11 12 3 25 Over 11 12 to 12 12 4 0 O...

Page 10: ...return piping to boiler Refer to Figures 6 3 and 6 4 Also consult Residential Hydronic Heating Installation and Design I B R Guide Maintain minimum inch clearance from hot water piping to combustible...

Page 11: ...l Zone Valve Controlled System System Circulator System Zone Valves Zone Circulators Full Port Isolation Valves Flow Check From System Full Port Isolation Valves Drain Valve Safety Relief Valve Pipe w...

Page 12: ...in 6 of floor or drain Drain Valve IWH Return IWH Supply Indirect Water Heater IWH Air Separator Air Vent Expansion Tank Backflow Preventer Fill Valve Cold Water Return Full Port Isolation Valves Unio...

Page 13: ...nt i e water heater cooking equipment B Connect boiler to gas supply system 1 Use methods and materials in accordance with local plumbing codes and requirements of gas supplier In absence of such requ...

Page 14: ...lectrical circuit must be run from the main electrical service with an over current device disconnect in the circuit A service switch is recommended and may be required by some local jurisdictions Con...

Page 15: ...15 FORCE E Installation Operating Service Manual 109444 03 12 19 Figure 8 1 Wiring Connection Diagram 8 Electrical continued...

Page 16: ...16 FORCE E Installation Operating Service Manual 109444 03 12 19 Figure 8 2 Schematic Ladder Diagram 8 Electrical continued...

Page 17: ...6 3 and 6 4 Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area 5 Starting with one circuit open zone valve or start circulator 6 Open drain valve 7 Open fill valve 8...

Page 18: ...18 FORCE E Installation Operating Service Manual 109444 03 12 19 Figure 9 1 Operating Instructions 9 System Start Up and Checkout continued...

Page 19: ...produces single flame Flame should be steady medium hard blue enveloping 3 8 to 1 2 inch of igniter sensor tip See Figure 9 3 9 System Start Up and Checkout continued 4 Turn OFF the electric switch to...

Page 20: ...sure 1 Install manometer on 1 8 outlet pressure tap on gas valve see Figure 9 2 Use of shutoff valve between manometer and gas valve can prevent pressure surge that blows out manometer fluid 2 Adjust...

Page 21: ...ermostat to call for heat and push TEST SETTINGS button on Hydrostat 3200 to simulate low water condition Red LOW WATER LED will illuminate and burner will shut down Release TEST SETTINGS button and b...

Page 22: ...ent Measurement Procedure See Figure 10 3 Measuring pilot flame current with micro ammeter a Pilot flame current in micro amps can be measured using any standard micro ammeter by inserting meter probe...

Page 23: ...to normal sequence If flame out of sequence remains longer than 10 seconds con trol will resume normal operation 1 hour after error is corrected Check for pilot flame Replace gas valve if pi lot flam...

Page 24: ...t pressure Checked gas manifold pressure Checked CO level in vent Checked vent damper operation Check ignition system safety shut off device Tested LWCO functionality Tested high limit operation Teste...

Page 25: ...d loose fitting clothing that is sufficiently tight around potential entry points for RCF dust 3 Gloves 4 Eye protection such as goggles safety glasses with side shields or full facepiece Take steps t...

Page 26: ...ion and there are no openings into chimney 3 Remove soot accumulations with wire brush and vacuum 4 Repair or replace deteriorated vent pipe and vent accessories 5 Inspect piping to determine that it...

Page 27: ...er Access Panel Connect Flame Rollout Switch wires E Inspect Water Piping 1 Check all system piping for leaks 2 Repair any leaks before placing back into service 12 Service and Maintenance continued F...

Page 28: ...p and Checkout Check LWCO Functionality S Check High Limit Control See Start up and Checkout Check High Limit Control T Check Thermostat Operation See Start up and Checkout Check Thermostat Operation...

Page 29: ...well S8610M Ignition Module Ignition module will sense pilot flame Once pilot flame is established ignition module opens gas valve and main burners will ignite When thermostat is satisfied ignition mo...

Page 30: ...30 FORCE E Installation Operating Service Manual 109444 03 12 19 3 1 2 5 4 6 7 On rear of boiler Rear of Boiler 3 13 How It Works continued...

Page 31: ...lable for use 3 Check electrical connections on boiler before proceeding see Figure 8 1 and Figure 8 2 4 Ensure 120VAC power polarity is correct and boiler is properly grounded 5 Controls are tested d...

Page 32: ...once to clear the pilot supply tubes of air Spark stops when pilot is lit Yes No Note If control goes into lockout or retry delay reset the Call For Heat Check continuity of ignition cable and ground...

Page 33: ...109871 02 1 109871 03 1 109871 04 1 109871 05 1 109871 06 1 109871 07 1 109871 08 1 109871 09 1 1B Canopy Gasket 109943 01 1 1C Canopy 109944 02 1 109944 03 1 109944 04 1 109944 05 1 109944 06 1 10994...

Page 34: ...03 1 109941 04 1 109941 05 1 109941 06 1 109941 07 1 109941 08 1 109941 09 1 2B Base Tray 2C Burner Tray 2D Base Side Insulation 2E Base Rear Insulation 2F Base Front Insulation 2G Drip Shields 2H Man...

Page 35: ...109958 03 1 109958 04 1 109958 05 1 109958 06 1 N A Gas Manifold N A 109958 07 1 109958 08 1 109958 09 1 3C 47 Orifice Natural Gas 109959 01 1 16 orifices 1 20 mm Orifice LP Gas 109954 01 1 16 orific...

Page 36: ...al 109444 03 12 19 Key No Description Part Number Quantity FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E 4A Hydrostat 3200 LWCO High Limit 109952 01 1 4B Honeywell S8610M EI...

Page 37: ...FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E 5A Wrap around Jacket Panel Not available 5B Jacket Vestibule Panel 109618 02 1 109618 03 1 109618 04 1 109618 05 1 109618 06 1 109618 07 1 109618 08 1 10...

Page 38: ...ORCE07E FORCE08E FORCE09E 6A Water Manifold 109968 01 1 6B Temperature Pressure Gauge 109966 01 1 6C 30 PSI Safety Relief Valve 109964 01 1 6D Drain Valve Source Locally 3 4 NPT boiler connection 6E V...

Page 39: ...FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E 7A Power Supply Harness 109963 01 1 7B Main Control Harness 109957 01 1 7C Ignition Harness 109953 01 1 Key No Description Part Number Q...

Page 40: ...Guide Appendix Combination Refrigeration Heating System Water Chiller Shut off valves Shut off valves Expansion Tank Circulator Supply main to combined heating cooling system Return main from combined...

Page 41: ...ing during these heating season shoulders is unlikely to cause problems Larger volume systems during the shoulder heating seasons or systems with aggressive set back or low temperature systems will ca...

Page 42: ...e by pass piping to reduce condensation Again this is a fixed system It can not adapt to variations in temperature and flow Best Alternative System by pass kit part number 107795 01 that addresses the...

Page 43: ...43 FORCE E Installation Operating Service Manual 109444 03 12 19...

Page 44: ...44 FORCE E Installation Operating Service Manual 109444 03 12 19...

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