Force FORCEOL115-E Installation, Operating And Service Instructions Download

Page: 59 / 68

106346-06 - 8/19

FORCE

Installation, Operating & Service Manual

Service Parts

(continued)

Item

Description

Part Number FORCEOL84-

FORCEOL115-

FORCEOL140-

FORCEOL182-

Complete Jacket Carton Includes:

Labels and Hardware

106443-02

106443-03

106443-04

Wrap Around Insulation

109553-02

109553-03

109553-04

Temperature & Pressure Gauge

105894-01

HydroStat 3250 Plus

Includes: Remote Mounting Kit & 36”

Sensor

109685-01

Electro-Well, 1/2” NPT x 3-1/4”

109566-01

Not

Shown Harness, Limit to Burner

109868-01

Baffle Kit

109991-01

109990-01

109558-01

Injector Kit

102827-01

Not

Shown

Relief Valve,

Conbraco,

” FIP x

”

FIP

#10-408-05 30PSI

Obtain Locally

#10-303-07 40 PSI

#10-303-10 50 PSI

5” Draft Regulator

6” Draft Regulator

Drain Valve,

” NPT

Circulator Flange

” NPT

Circulator

Gasket

Grundfos

Circulator

Grundfos Alpha2

Summary of Contents for FORCEOL115-E

Page 1: ...ions for future reference Models FORCEOL84 E FORCEOL115 E FORCEOL140 E FORCEOL182 E Manual Contents Page General Information 5 Pre installation 7 Packaged Boiler Assy Trim Controls 9 Water Boiler Pipi...

Page 2: ...Current Edition of American Society of Mechanical Engineers ASME CSD 1 Controls and Safety Devices for Automatically Fired Boilers for assembly and operations of controls and safety devices D All wiri...

Page 3: ...anual for details It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete including verifyin...

Page 4: ...nector or smokepipe joints may be signs of condensing flue gases Flue gas condensate is corrosive which requires special consideration and must be addressed immediately Refer to Natural Draft Venting...

Page 5: ...RE 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 SMOKE...

Page 6: ...mum Working Pressure Water 30 PSI Shipped From Factory Standard 50 PSI Optional Boiler Model Burner Capacity Minimum Chimney Recommendations Direct Vent System GPH MBH Round In Dia Rectangle In x In H...

Page 7: ...eway cleaning FORCEOL084 E through FORCEOL140 E 30 for flueway cleaning FORCEOL182 E b Clearance from Jacket Left Side Panel 19 for burner swing door if opened fully with burner mounted otherwise 1 wi...

Page 8: ...he Installation of Oil Burning Equipment 2 FORCE OIL boilers can be installed in rooms with clearances from combustible material as listed above Listed clearances cannot be reduced for alcove or close...

Page 9: ...Remove skid from underneath the 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 Ste...

Page 10: ...be lifted off mounting bracket and set aside during servicing c The door mounting hardware is reversible from left side hinge as shipped to right side hinge To reverse hinge arrangement see Figure 4A...

Page 11: ...346 06 8 19 FORCE Installation Operating Service Manual Figure 4B Top View Burner Swing Door Mounted to Cast Iron Block Assembly Jacket Removed for Clarity 3 Packaged Boiler Assembly Trim Controls con...

Page 12: ...tighten door hardware and always start with the right side cap screw first Use an alternating tightening method from right side tap bolt to left side tap bolt to tighten door equally until sealed wit...

Page 13: ...all joints until watertight and NPT 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 al...

Page 14: ...d side jacket panel with cable clamps with self tapping sheet metal screws included as shown in Figure 5 3 Install return injector piping and relief valve refer to Figure 7 Locate the return pipe fitt...

Page 15: ...d Figure 9 FORCEOL084E To install flueway baffle in 2nd 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...

Page 16: ...sembly Trim Controls continued 7 Close the burner swing door and securely seal the door to the boiler front section by reinstalling the hardware and securing the door using procedure previously outlin...

Page 17: ...SYSTEM SUPPLY AND RETURN PIPING TO BOILER See Figures 10A and 10B Also consult Residential Hydronic Heating Installation and Design I B R Guide 1 Ifthisboilerisusedinconnectionwithrefrigeration syste...

Page 18: ...18 106346 06 8 19 FORCE Installation Operating Service Manual Figure 10A Recommended Water Piping for Circulator Zoned Heating Systems Supply Side Circulator 4Water Boiler Piping continued...

Page 19: ...19 106346 06 8 19 FORCE Installation Operating Service Manual Figure 10B Recommended Water Piping for Zone Valve Zoned Heating Systems Supply Side Circulator 4Water Boiler Piping continued...

Page 20: ...er boiler is just above the highest 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...

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

Page 22: ...shall be inspected for integrity as well as for proper draft and condensate control Some jurisdictions require the use of a liner when changing fuel types Some jurisdictions require the use of a line...

Page 23: ...E 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 AIR GAP APPR...

Page 24: ...listing and manufacturer s instructions b Steel pipe having resistance to corrosion and heat with a minimum wall thickness of 24 Gauge 0 024 DANGER Any signs of condensate seepage at the base of the...

Page 25: ...s condensate must be relined according to NFPA 31 United States or CSA B139 Canada CAUTION Use the chimney venting tables as a guide It is highly recommended that any borderline application should res...

Page 26: ...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 venting system must be installed...

Page 27: ...Separate the vent hood 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...

Page 28: ...installed in accordance with the applicable provisions of any local codes and in UnitedStates requirementsofNFPA31 Standard for the Installation of Oil Burning Equipment and NFPA 211 Standard for Chim...

Page 29: ...into the adapter sampling port 9 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 scr...

Page 30: ...r pipe clamp halves with 1 4 20 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 t...

Page 31: ...ee 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 below stop bead...

Page 32: ...t and plumb Refer to the vacuum relief 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...

Page 33: ...be influenced 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 a...

Page 34: ...34 106346 06 8 19 FORCE Installation Operating Service Manual Figure 27 Schematic Wiring Diagram HydroStat 3250 Control with Beckett AFG Series Burners 8 Electrical continued...

Page 35: ...35 106346 06 8 19 FORCE Installation Operating Service Manual Figure 28 Schematic Wiring Diagram HydroStat Control to Beckett NX Burners 8 Electrical continued...

Page 36: ...e 29 Schematic 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...

Page 37: ...pe or 3 8 OD copper 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...

Page 38: ...mmendations on the proper connections 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 lin...

Page 39: ...tained in 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 instru...

Page 40: ...e c Disconnect the copper oil connector tube from nozzle line d Loosen the two screws securing igniter retaining clips and rotate both clips to release the igniter baseplate The igniter should pop up...

Page 41: ...41 106346 06 8 19 FORCE Installation Operating Service Manual Figure 32 L1 and V1 Head Electrode Positioning and Gun Setting Beckett AFG 10 System Start Up continued...

Page 42: ...nt fitting on fuel pump 2 PRESS RED RESET BUTTON on primary control hold for ten 10 seconds and release to reset primary control 3 TURN ON BURNER service switch and allow burner to run until oil flows...

Page 43: ...e b FORCEOL182 E Beckett MD V1 variable Head burners have the ability to control air by moving the head It might be necessary to move the head forward or back one position at a time to optimize the sm...

Page 44: ...sandhold the reset button for 15 seconds until the yellow light turns on This indicates that the button has been held long enough Release the reset button The yellow light will turn off and the burner...

Page 45: ...he piping to the oil tank Check the oil nozzle oil supply and oil filter b Check Safety Features Safe Start Place a jumper across cad cell terminals Follow procedure to turn on burner Burner must not...

Page 46: ...r light should illuminate and the burner circuit B1 B2 should de energize 6 CHECK AFTERMARKET LOW WATER CUT OFF CONTROL if required on this boiler application See Appendix B at the rear of this manual...

Page 47: ...same function THIS 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...

Page 48: ...ter treatment company 4 Make pH or Alkalinity Test After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by draw...

Page 49: ...eeze damage 2 Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners 3 Always keep the manual fuel supply valve shut off if the burner is...

Page 50: ...tion for the other 2nd pass flue way 6 Vacuum the loose debris in the bottom of the combustion chamber and smoke box B CLEAN THE COMBUSTION CHAMBER Use a wire or fiber bristle brush to clean the surfa...

Page 51: ...if the boiler is connected to a dirty or inadequate chimney The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically...

Page 52: ...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 to...

Page 53: ...O2 reading in the breeching The smaller the firing rate the greater effect an air leak can have on CO2 readings 5 DIRT A fuel filter is a good investment Accidental accumulation of dirt in the fuel sy...

Page 54: ...ht then shut down after a short time then restart after one 1 minute a CAD cell is defective b Air leaking into oil line causing flame out c Defective nozzle causing flame to be erratic d Excessive ai...

Page 55: ...55 106346 06 8 19 FORCE Installation Operating Service Manual All FORCE Repair Parts may be obtained by contacting your local Ferguson branch 15 Service Parts...

Page 56: ...56 106346 06 8 19 FORCE Installation Operating Service Manual Bare Boiler Assembly 15 Service Parts continued...

Page 57: ...des Block Assembly and Smoke Box 109554 02 1 1 109554 03 1 109554 04 1 1B Smoke Box Includes Sealant and Hardware 109555 01 1 1 1 1 1C Burner Swing Door Assembly 109556 01 1 1 1 1 1D Cleanout Cover As...

Page 58: ...58 106346 06 8 19 FORCE Installation Operating Service Manual Jacket Assembly 15 Service Parts continued...

Page 59: ...1 1 1 2D HydroStat 3250 Plus Includes Remote Mounting Kit 36 Sensor 109685 01 1 1 1 1 2E Electro Well 1 2 NPT x 3 1 4 109566 01 1 1 1 1 Not Shown Harness Limit to Burner 109868 01 1 1 1 1 2F Baffle K...

Page 60: ...Control Beckett GeniSys 7505B Obtain Locally 1 1 1 1 5 FORCEOIL Oil Burners Item No Description Part No FORCEOL140 E FORCEOL182 E 3 DIRECT VENT KITS AND PARTS Not Shown Direct Vent Conversion Kit 1064...

Page 61: ...61 106346 06 8 19 FORCE Installation Operating Service Manual Beckett AFG Burner 15 Service Parts continued...

Page 62: ...ube Assembly 5636 5636 5636 5636 Electrode Clamp 149 149 149 149 Electrode Clamp Screw 4219 4219 4219 4219 Electrode Insulator Assembly 5780 5780 5780 5780 Spider Spacer Assembly 5503 5503 5503 5503 E...

Page 63: ...63 106346 06 8 19 FORCE Installation Operating Service Manual Beckett NX Burner 15 Service Parts continued...

Page 64: ...ear Access Door 15 Igniter Electronic 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...

Page 65: ...s 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 bu...

Page 66: ...LWCO Location Wiring of Typical LWCO Appendix A Aftermarket Low Water Cut Off LWCO On Hot Water Boilers WARNING DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off LWCO Onl...

Page 67: ...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 LWCO Generate a boiler demand by turning...

Page 68: ...__________________________________________________ __________________________________________________________________________________________________ __________________________________________________...

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