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Force FORCEOL Series Installation, Operating And Service Instructions Download Page 56

56

Bare 

Boiler Assembly

1A

1A

A

1Z

1Y

1Y

1X

1G

1H

1L

1K

1H

1M

1J

1R

1Q

1N

1P

1W

1T

1S

1V

1U

1D

1D

1F

1E

1C

1C

1B

1F

1E

xV

:  Repair Parts 

(continued)

Summary of Contents for FORCEOL Series

Page 1: ...al Number Installation Date Heating Contractor Phone Number Address 106346 02 8 15 Price 5 00 9700609 As an ENERGY STAR Partner U S Boiler Company Inc has determined that the FORCE OIL Series boilers...

Page 2: ...sections may be attributed to the manufacturing process as well as condensation during storage Surface rust is normal and does not affect the performance or longevity of a boiler All boilers must be i...

Page 3: ...onsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete including verifying that the limit sensor is fully...

Page 4: ...peration and must be installed so there are provisions for adequate combustion and ventilation air This boiler is supplied with controls which may cause the boiler to shut down and not re start withou...

Page 5: ...GAUGE RELIEF VALVE BECKETT AFG BURNER SHOWN SPANNER BAR W ADJUSTABLE LEGS 1 1 2 NPT SYSTEM SUPPLY CONNECTION 21 3 8 31 7 8 BOILER CONTROL NOTES 1 THIS DIMENSION INCREASES AND IS CONTROLLED BY SMOKEPIP...

Page 6: ...30 6 14 46 27 29 658 NOTE 1 Maximum Working Pressure Water 30 PSI Shipped From Factory Standard 50 PSI Optional Boiler Model No Burner Capacity AFUE Minimum Chimney Requirements Direct Vent System GPH...

Page 7: ...hrough FORCEOL147 30 for flueway cleaning FORCEOL189 b Clearance from Jacket Left Side Panel 19 for burner swing door if opened fully with burner mounted otherwise 1 with burner removed 12 access clea...

Page 8: ...y with American National Standard ANSI NFPA 31 Standard for the Installation of Oil Burning Equipment 2 FORCEOL boilers can be installed in rooms with clearances from combustible material as listed ab...

Page 9: ...he boiler Step 6 Lower pipe handles until front adjustable legs touch floor If necessary place wooden blocks under front legs before lowering to provide hand clearance Step 7 To lower rear of boiler t...

Page 10: ...door mounting hardware is reversible from left side hinge as shipped to right side hinge To reverse hinge arrangement see Figure 4A Lift door off mounting bracket and set aside Remove mounting bracke...

Page 11: ...11 Figure 4B Top View Burner Swing Door Mounted to Cast Iron Block Assembly Jacket Removed for Clarity III Packaged Boiler Assembly Trim Controls continued...

Page 12: ...ap screw first Use an alternating tightening method from right side tap bolt to left side tap bolt to tighten door equally until sealed without applying excessive torque Never tighten left side flange...

Page 13: ...connection on tee is positioned to allow clearance for relief valve discharge Step 2 Locate the relief valve piping supplied with boiler Apply thread sealant to all joints prior to assembly Thread th...

Page 14: ...ps in parts carton Secure sensor wire to top jacket panel and side jacket panel with cable clamps with self tapping sheet metal screws included as shown in Figure 5 3 Install return injector piping an...

Page 15: ...To install flueway baffle in 3rd pass on left side of boiler hold baffle with word Left readable at the top Slide baffle in flueway until position tab touches fins on left side of 3rd pass flueway To...

Page 16: ...16 III Packaged Boiler Assembly Trim Controls continued Figure 9 Baffle Orientation in Flueways...

Page 17: ...ER See Figures 10A and 10B Also consult Residential Hydronic Heating Installation and Design I B R Guide 1 If this boiler is used in connection with refrigeration systems the boiler must be installed...

Page 18: ...18 Figure 10A Recommended Water Piping for Circulator Zoned Heating Systems Supply Side Circulator IV Water Boiler Piping continued...

Page 19: ...19 Figure 10B Recommended Water Piping for Zone Valve Zoned Heating Systems Supply Side Circulator IV Water Boiler Piping continued...

Page 20: ...ghest water containing cavity of the boiler that is a hot water boiler must be full of water to operate safely 5 If it is required to perform a long term pressure test of the hydronic system the boile...

Page 21: ...o refer to Figure 10A and 10B Figure 12A Indirect Water Heater Piping w Supply Side Circulator on Circulator Zoned Heating System Refer to instructions furnished with Indirect Water Heater for additio...

Page 22: ...pliances a Loose Mortar Loose mortar could be an indication of a prior history of condensing flue gases upon the inside walls of the chimney Colder climates are more susceptible to this VI natural dra...

Page 23: ...tinued THIMBLE CLEANOUT DRAFT REGULATOR DILUTION AIR BOILER FRONT NOTE FIRECLAY TILE LINED CHIMNEY ALL HORIZONTAL VENT PIPE SHOULD SLOPE UPWARD NOT LESS THAN ONE INCH IN FOUR FEET SLOPE UP VENT SYSTEM...

Page 24: ...propensity to create condensate The higher the stack temperature the greater the amount of draft that can be generated A lower stack temperature not only reduces the amount of draft that can be create...

Page 25: ...condensation in the chimney or chimney connector Consult with your local chimney professional for recommendations VI Natural Draft Venting Chimney continued E Minimum Clearances See Figure 2A for deta...

Page 26: ...ct Vent Hood Assembly minimum clearance to combustible material is 0 4 Maximum wall thickness that FDVS vent termination may be installed through is 12 Figure 16 Vent Terminal Location WARNING This ve...

Page 27: ...tee from the vent hood body and set aside for later use 5 After determining the location of the venting system termination cut the square hole in the wall sized according to L dimension in Table 5 se...

Page 28: ...quirementsofNFPA31 StandardfortheInstallation ofOil BurningEquipmentandNFPA211Standardfor Chimney Fireplaces Vents and Solid Fuel Burning Appliances latest editions 2 A vent pipe connector designed fo...

Page 29: ...After initial boiler start up and burner testing adjustment are completed apply high temperature sealant under the head of sampling port plug screw and install the screw in the sampling port tighteni...

Page 30: ...0 bolts and square nuts position the inner pipe clamps from the end of inner vent pipe on vent pipe opposite ends 9 Remove any oil and grease from inside of each end of the inner vent pipe 10 Apply a...

Page 31: ...m burner cover See Figure 26 5 Start at burner and work towards Direct Vent termination air intake 6 Procure a 2 ft section of 4 diameter galvanized single wall vent pipe cut off the crimped pipe end...

Page 32: ...lief valve manufacturer s instructions for details 14 Install remainder of air intake piping to Direct Vent Termination air intake collar securing each joint with at least 3 sheet metal screws install...

Page 33: ...by drafts hot or cold water pipes lighting fixtures television rays of the sun or near a fireplace Keep large furniture away from thermostat so there will be free movement of room air around this cont...

Page 34: ...II Electrical continued Figure 27 Schematic Wiring Diagrams Cold Start Control with Beckett AFG Burners REFER TO FIGURE 30 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OP...

Page 35: ...III Electrical continued Figure 28 Schematic Wiring Diagram Cold Start Control with Beckett NX Burners REFER TO FIGURE 30 FOR SCHEMATIC WIRING DIAGRAM OF APPROPRIATE BURNER AND OIL PRIMARY CONTROL OPT...

Page 36: ...36 Figure 29 Schematic Wiring Diagrams HydroStat 3250 Control with Beckett AFG Series Burners VIII Electrical continued...

Page 37: ...matic Wiring Diagrams NOTE APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC REFER TO Figure 28 NOTE APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER C...

Page 38: ...per tubing Copper tubing shall have a 032 minimum wall thickness WARNING Under no circumstances can copper with sweat style connectors be used NOTICE Some jurisdictions require the use of a fusible sh...

Page 39: ...ections for a two pipe system Some manufacturers require the insertion of a bypass plug 3 Under no circumstances is a manual shutoff valve to be located on the return line of a two pipe system Acciden...

Page 40: ...this manual 2 Confirm all electrical water and oil supplies are turned off at the source and that the vent is clear from obstructions WARNING Completely read understand and follow all instructions in...

Page 41: ...rews securing the rear door then swing to the right and down f Loosen splined nut g Lift up the igniter baseplate and simultaneously remove nozzle line assembly from burner by drawing it straight back...

Page 42: ...42 X System Start Up continued Figure 33 L1 and V1 Head Electrode Positioning and Gun Setting Beckett AFG...

Page 43: ...niter will operate but the oil valve will remain closed Refer to Oil Primary Control Instructions for more details 5 Adjust oil pressure a When checking a fuel unit s operating pressure a reliable pre...

Page 44: ...n or remove any oil line fittings while burner is operating 4 FLAME FAILURE The FORCEOL boiler controls operate the burner automatically If for unknown reasons the burner ceases to fire and the reset...

Page 45: ...s the yellow light will turn off and the control will automatically return to standby mode iii Limited Recycle This feature limits the number of recycle trials for each call for heat to a maximum of t...

Page 46: ...e of cad cell and see that cell is X System Start Up continued securely in socket Check gasket around perimeter of ignitor lid for proper seal If gasket is missing or damaged replace gasket Room light...

Page 47: ...IS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load dec...

Page 48: ...scribed test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper except...

Page 49: ...ntinued 3 Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time 4 To recondition the heating system in the fall season after a prolonged shut down...

Page 50: ...bustion chamber and smoke box B Clean the Combustion Chamber Use a wire or fiber bristle brush to clean the surfaces of the combustion chamber Vacuum all of the loose debris in the bottom of the combu...

Page 51: ...y The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions A clean...

Page 52: ...Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separatel...

Page 53: ...le or nozzle strainer and produce a poor spray pattern from the nozzle The smaller the firing rate the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same am...

Page 54: ...g flame to leave burner head e Excessive back pressure causing flame to be erratic 3 Control locks out after Trial For Ignition TFI a No oil to burner b Shorted electrodes c Nozzle clogged d Airflow t...

Page 55: ...55 XV Repair Parts All FORCE Repair Parts may be obtained by contacting your local Ferguson branch...

Page 56: ...56 Bare Boiler Assembly 1A 1AA 1Z 1Y 1Y 1X 1G 1H 1L 1K 1H 1M 1J 1R 1Q 1N 1P 1W 1T 1S 1V 1U 1D 1D 1F 1E 1C 1C 1B 1F 1E XV Repair Parts continued...

Page 57: ...Bracket 80861340 2 2 2 2 Mount Burner 3 3 3 3 1J Cast Iron Burner Swing Door Only 102421 01 1 1 1 1 1K Burner Swing Door Insulation Less Pockets 100039 01 1 1 1 1 1L 1 2 Dia Rope Gasket Burner Swing...

Page 58: ...58 Jacket Assembly XV Repair Parts continued...

Page 59: ...o Description Part No FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189 2 JACKET ASSEMBLY 2 Complete Jacket Kit 106443 02 1 1 Complete Jacket Kit 106443 03 1 Complete Jacket Kit 106443 04 1 XV Repair Parts...

Page 60: ...60 Water Boilers Trim and Controls XV Repair Parts continued...

Page 61: ...ll 123872A Immersion Well 1 2 NPT 3 Insulation 80160497 1 1 1 1 3G Limit Rated Temperature Sensor Only 12 Length 103195 01 1 1 1 1 HydroStat 3250 Plus Burner Harness Assembly Does Not Include Sensor 1...

Page 62: ...62 Beckett AFG Burner XV Repair Parts continued...

Page 63: ...149 Electrode Clamp Screw 4219 4219 4219 4219 Electrode Insulator Assembly 5780 5780 5780 5780 Spider Spacer Assembly 5503 5503 5503 5503 Escutcheon Plate 3493 3493 3493 5941 Adjusting Plate Assembly...

Page 64: ...64 Beckett NX Burner XV Repair Parts continued...

Page 65: ...ctronic 51771U 16 Inlet Air Box 1010U 18 Inlet Air Adapter Outside Air Kit 1014U 19 Nozzle Line Electrode and Head Assembly Specify 20 Motor 21805U Mounting Screws 1 4 20 x 7 8 4189 21 Primary Safety...

Page 66: ...Assy Cover Sleeve FDVS 5 100236 02 2 2 Assy Cover Ring FDVS 5 100237 02 2 2 Clamp Inner Pipe FDVS 5 Half 100238 02 4 4 6 FLEX OIL VENT PIPE FOR DIRECT VENT Not Shown 5 Dia x 5 ft FOVP 505 100211 02 1...

Page 67: ...optional Burner manufacturer has preset single stage fuel pump to settings shown in table above Two stage fuel pump is factory set at 140 PSI and must be readjusted to settings shown above during burn...

Page 68: ...pically in residential applications a probe type LWCO is used instead of a float type due to their relative costs and the simplicity of piping for a probe LWCO How to Pipe A tee is commonly used to co...

Page 69: ...d if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application How to Test Shut off fuel supply Lower water level until water level is BELOW the...

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