INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FORCESTM™ SERIES GAS BOILER 9700609 For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label. Boiler Model Number FORCESTEAM0 _ Heating Contractor Boiler Serial Number Installation Date Phone Number Address 106324-04 - 4/18 Price - $5.
WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler. INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician follow the Service checklist near the end of this manual. IF YOU ARE NOT QUALIFIED to install or service boilers, do not install or service this one. THE BOILER MAY LEAK WATER at the end of its useful life. Be sure to protect walls, carpets, and valuables from water that could leak from the boiler.
WARNINGS FOR THE INSTALLER READ THIS ENTIRE MANUAL before attempting installation, start-up, or service. Improper installation, adjustment, alteration, service, or maintenance may cause serious property damage, personal injury, or death. INSTALL ALL GUARDS, cover plates, and enclosures before operating the boiler. SIZE THE BOILER PROPERLY relative to the design heat load or, if using domestic hot water priority, the peak hot water load, whichever is larger.
TABLE OF CONTENTS I. Product Description.................................................................................... 4 II. Specifications............................................................................................ 5 III. Pre-Installation........................................................................................... 6 IV. Locating the Boiler..................................................................................... 6 V.
II. Specifications FIGURE 1: FORCESTM BOILERS - GENERAL CONFIGURATION TABLE 1: FORCESTM SPECIFICATIONS Dimensions (in inches) Recommended Min. Round Chimney Size (Diameter x Height) (1) Boiler Model Approx. Shipping Weight Lbs. FORCESTM03 350 12¾ 4 FORCESTM04 420 16 5 FORCESTM05 485 19¼ FORCESTM06 555 22½ 6 6" x 15 ft. FORCESTM07 620 25¾ FORCESTM08 690 29 7 7" x 15 ft. 'A' 'B' 'C' 28 40-7/16 30 'D' Gas Conn. (NPT) Water Volume (Gal.) Steam Boiler (2) 4" x 15 ft. 5.
I. Pre-Installation 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the requirements of the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
IV. Locating the Boiler (continued) FIGURE 2: FORCESTM BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. 3) The boiler must be installed on a hard level surface. 4) Do not install this boiler in a location where gasoline or other flammable vapors or liquids will be stored or used. Do not install this boiler in an area where large amounts of airborne dust will be present, such as a workshop.
VI. Venting Vent installation must be in accordance with local building codes, or the local authority having jurisdiction, or the National Fuel Gas Code, ANSI Z223.1/NFPA 54. 1. A typical vent installation is illustrated by Figure 3. The components of vent installation are the vent damper (if used), vent connector and chimney. 2. Install vent damper (see Figure 4) as follows: a) Open vent damper carton and remove installation instructions. Read the instructions thoroughly before proceeding.
VI. Venting (continued) FIGURE 4: VENT DAMPER INSTALLATION DETAILS Lowest discharge opening TABLE 2: ROOF SLOPE HEIGHTS Listed cap Listed gas vent Roof Slope 12 x Roof pitch is x/12 H (minimum) Minimum height from roof to lowest discharge opening H (minimum) ft m Flat to 6/12 1.0 0.30 Over 6/12 to 7/12 1.25 0.38 Over 7/12 to 8/12 1.5 0.46 Over 8/12 to 9/12 2.0 0.61 Over 9/12 to 10/12 2.5 0.76 Over 10/12 to 11/12 3.25 0.99 Over 11/12 to 12/12 4.0 1.22 Over 12/12 to 14/12 5.
VII. Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at a line pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or Chapter 2 of the National Fuel Gas Code. Figure 6 shows typical gas piping connection to the FORCESTM boiler. A sediment trap must be installed upstream of all gas controls.
VIII. System Piping CAUTION • INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER (DRIPPING, SPRAYING, RAIN, ETC.) DURING APPLIANCE OPERATION AND SERVICE (CIRCULATOR REPLACEMENT, ETC.). • OPERATION OF THIS BOILER IN A SYSTEM HAVING SIGNIFICANT AMOUNTS OF DISSOLVED OXYGEN CAN CAUSE SEVERE HEAT EXCHANGER CORROSION DAMAGE.
VIII. System Piping (continued) Piping Installation 1) Remove parts bag from boiler crate. 2) Install safety valve (spindle must be in vertical position) into tapping on boiler left side (see Figure 1) using the 3/4” NPT nipple and elbow supplied. 3) Pipe the discharge of the safety relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe.
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IX. Indirect Water Heater Piping All FORCESTM series boilers are equipped with tappings to permit the connection of a Link SL™ Indirect Water Heater, or other indirect water heater. In this type of system, hot boiler water is drawn from below the water line and passed through the heat exchanger in the indirect water heater. This section describes boiler-side piping only. Refer to Link SL™ Installation, Operating and Service Instructions for additional information.
X. Electrical WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ANSI/NFPA 70) 1) 120 Volt Wiring - The boiler should be provided with its own 15A branch circuit with fused disconnect. All 120 volt connections are made inside the junction box on the left side of the boiler.
X. Electrical (continued) Indirect Water Heater Wiring Figure 10 shows field wiring for an indirect water heater. A Honeywell R845A or equivalent DPST relay and transformer is required. The high limit described in Part IX must also be supplied by the installer. A call for heat from the indirect water heater thermostat will energize the relay making both sets of contacts. One set of these contacts then energizes the circulator.
X. Electrical (continued) FORCESTM Control System – Sequence of Operation (Refer to Figures 11 & 12 for ladder and connection diagrams) Sequence of Operation, Intermittent Ignition 1) When the boiler is energized, 24 volts is immediately applied to terminals “1” (blue) and “4” (yellow) on the vent damper. Assuming that there is no call for heat, and that the damper switch is in the “automatic” position, the damper will close.
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XI. System Start-up Use the following procedure for initial start-up of the boiler: 1) Make sure that the boiler is filled with water to the normal water line (28 3/4 inches above the floor or pad on which the boiler is installed) 2) Check all new gas piping for leaks and purge piping sections that are filled with air. See Part 4 of the National Fuel Gas Code for additional information on testing and purging gas lines. WARNING • NEVER USE A FLAME TO CHECK FOR GAS LEAKS.
XI. System Start-up (continued) WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVERFIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 16) Check the manifold pressure and adjust if necessary. To do this, use the following procedure: a) Connect a manometer to the inlet pressure tap on the gas valve (see Figure 16). b) Check the inlet pressure with all gas appliances on and off.
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XI. System Start-up (continued) FIGURE 15: MAIN BURNER FLAME - 1” BURNERS 17) Test thermostat operation while the boiler is running. Turn the thermostat to the lowest setting. Both pilot burner and main burners should stop firing. Raise the thermostat back to the highest setting. The pilot burner and main burners should relight. 18) Verify low water cutoff operation while the boiler is running. Slowly open drain valve and drain boiler until the water level drops below low water cutoff line.
XI. System Start-up (continued) e) Turn off gas supply to boiler per the Operating Instructions - see Figure 14. Drain hot water from boiler through boiler drain valve to a location where hot water can be safely discharged. Refill the boiler to normal water line level. If water in the gauge glass does not look clear, repeat above boil-out procedure again until water is clears. f) Reinstall safety valve and related piping. g) Conduct pH and Alkalinity test of water in the system.
XII. Service Instructions On a continuous basis: 1) Keep the area around the boiler free and clear from combustible materials, gasoline, and other flammable vapors and liquids. 2) Keep the area around the boiler and boiler room ventilation openings clear of objects which might obstruct the flow of combustion and ventilation air. Every three months: Boiler water must be monitored throughout the heating season. Boiler water must be tested every three (3) months for the constituents shown in Table 3.
XII. Service Instructions (continued) CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. VERIFY PROPER OPERATION AFTER SERVICING. 11) Inspect the boiler and system for leaks. 12) Inspect the HydroLevel CG400A low water cut-off: Remove and inspect the probe for scale and sediment buildup. Clean any sediment or scale from the probe with a scouring pad or steel wool.
XII. Service Instructions (continued) CAUTION If, during normal operation, it is necessary to add water to this boiler more frequently than once a month, consult a qualified service technician to check your system for leaks. A leaky system will increase the volume of make-up water supplied to the boiler which can significantly shorten the life of the boiler. Entrained in make-up water are dissolved minerals and oxygen.
XII. Service Instructions (continued) WARNING SOOT DEPOSITS IN THE FLUE PASSAGES ARE A SIGN THAT THE BOILER MAY BE OPERATING AT HIGH CARBON MONOXIDE (CO) LEVELS. AFTER CLEANING THE BOILER OF SOOT DEPOSITS, CHECK THE CO LEVEL IN THE FLUE GAS TO INSURE THAT THE BOILER IS OPERATING PROPERLY. If it is necessary to check CO, use a combustion analyzer, or other instrument which is designed to measure CO in flue gas.
XIII. Troubleshooting The following pages contain troubleshooting charts for use in diagnosing control problems. To use these charts, go to the box marked “Start” at the top of the chart on page 30 or 32 and follow the appropriate path though the chart until a box with a list of possible causes is reached. If the problem is known to be within the ignition system, go directly to the ignition system troubleshooting guide for the boiler on page 32.
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XIV. Repair Parts All FORCESTM™ Repair Parts may be obtained by contacting your local Ferguson branch.
XIV. Repair Parts (continued) Key No. 1 Description Heat Exchanger Assembly (Complete) 2 Base Tray 3 Base Wrapper 4 Burner Tray 5 Base Front Panel Assembly (includes insulation) 6 Burner Access Panel 34 Part No.
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XIV. Repair Parts (continued) Key No. 7 8 Description Base End Insulation Base Rear Insulation Part No.
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XIV. Repair Parts (continued) Key No. Description 41 Main Burner with Pilot Bracket 42 Main Burner Less Pilot Bracket 43 1 1 1 1 1 2 4 6 8 11 13 --- --- --- --- --- 104810-04 --- 1 --- --- --- --- 104810-05 --- --- 1 --- --- --- 104810-06 --- --- --- 1 --- --- 104810-07 --- --- --- --- 1 --- 104810-08 --- --- --- --- --- 1 822712 3 --- --- --- --- --- Nat. Gas Main Burner Orifice, #45 822711 --- 5 7 --- --- --- Nat.
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XIV. Repair Parts (continued) Key No. Part Number Description Quantity FORCESTM03 FORCESTM04 FORCESTM05 FORCESTM06 FORCESTM07 FORCESTM08 * Damper Wire Harness 105083-01 1 1 1 1 1 1 * Blocked Vent Switch Harness 104965-01 1 1 1 1 1 1 * J-Box FRS Harness 105084-01 1 1 1 1 1 1 * CG400A L.W.C.
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Appendix A - Tapping Locations FIGURE A1: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES) TABLE A1: TRIM AND CONTROL INSTALLATION IN SECTION TAPPINGS 42 Tapping Size (NPT) Steam Boiler with Probe LWCO A 2 Supply B ½ Bush to ¼ Pressure Gauge C ½ Gauge Glass D 2 Return E ¾ 3" Nipple & Street Elbow Safety Relief Valve F 2 Bush to ¾ Drain Valve and/or Optional Return G 2 Optional Supply (FORCESTM03 - FORCESTM06) Required Supply (FORCESTM07 - FORCESTM08) H ¾ Bush to ¼ & Syphon, Limit
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