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INSTALLATION, OPERATING
SERVICE INSTRUCTIONS
CAST IRON OIL-FIRED BOILER
As an ENERGY STAR
U.S. Boiler Company, Inc. has
determined that the FORCE OIL
Series boilers meets the ENERGY
STAR
efficiency established by the United
States Environmental Protection
Agency (EPA).
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 Part Number
FORCEOIL _ _ _
Heating Contractor
Address
106346-02 - 8/15
FORCEOL™ SERIES
Partner,
®
guidelines for energy
®
Boiler Serial Number
AND
Installation Date
Phone Number
Price - $5.00
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Table of Contents
Related Manuals for Force FORCEOL147
Summary of Contents for Force FORCEOL147
- Page 1 FORCEOL™ SERIES CAST IRON OIL-FIRED BOILER As an ENERGY STAR Partner, ® U.S. Boiler Company, Inc. has determined that the FORCE OIL Series boilers meets the ENERGY STAR guidelines for energy ® efficiency established by the United States Environmental Protection Agency (EPA).
- Page 2 IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made.
- Page 3 DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
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Page 4: Table Of Contents
WARNING This boiler contains very hot water under high pressure. DO NOT unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. -
Page 7: Pre-Installation
II: PRE-INSTALLATION A. INSPECT SHIPMENT carefully for any signs of • 24" for flueway cleaning (FORCEOL084 damage. through FORCEOL147). • 30" for flueway cleaning (FORCEOL189) 1. All equipment is carefully manufactured, inspected b. Clearance from Jacket Left Side Panel - and packed. - Page 8 Direct Vent Boiler Oil Burner Conversion Kit FOVP Carton Part No. Model No. Part No. Part No. 100211-02 - 5 ft. FORCEOL147 106109-03 100212-02 - 10 ft. 106401-01 100213-02 - 15 ft. FORCEOL189 103369-01 100214-02 - 20 ft. FDVS DIRECT 3"...
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Page 9: Packaged Boiler Assy. - Trim & Controls
III: PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS A. REMOVE CRATE. blocks under front legs before lowering to provide hand clearance. 1. Remove all fasteners at crate skid. Step 7. To lower rear of boiler, tilt unit slightly 2. Lift outside container and remove all other forward by pushing on smokebox collar or lift inside protective spacers and bracing. - Page 10 III: Packaged Boiler Assembly - Trim & Controls (continued) Figure 4A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured Step 2. Loosen and remove right side latching • Remove mounting bracket and hardware hardware (3/8"...
- Page 11 III: Packaged Boiler Assembly - Trim & Controls (continued) Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)
- Page 12 III: Packaged Boiler Assembly - Trim & Controls (continued) 3. TO CLOSE BURNER SWINg DOOR (see Figures Step 4. Use a hand wrench to tighten door hardware 4A and 4B): and always start with the right side cap screw first. Use an alternating tightening Step 1.
- Page 13 III: Packaged Boiler Assembly - Trim & Controls (continued) 3. Inspect burner swing door insulation for damage and Step 2. Locate the relief valve piping supplied proper type. with boiler. Apply thread sealant to all joints prior to assembly. Thread the ¾" NPT street By design, cast bars on front section between the elbow onto tee listed above.
- Page 14 III: Packaged Boiler Assembly - Trim & Controls (continued) Figure 6: Limit Sensor Insertion Step 2. Locate (2) 5/8” cable clamps in parts carton. Secure burner wiring harness to front of jacket right side panel with cable Figure 7: Return Injector Piping and clamps and existing jacket screws at top and Relief Valve Assembly Details mid-point.
- Page 15 To install P/N 100081-01 FORCEOL115 P/N 102066-01 flueway baffle in 2 pass on left side of FORCEOL147 boiler, hold baffle with word “Left” readable None P/N 100042-01 at the top. Slide baffle in flueway until FORCEOL189 position tab touches fins on left side of 3 Step 3.
- Page 16 III: Packaged Boiler Assembly - Trim & Controls (continued) Figure 9: Baffle Orientation in Flueways...
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Page 17: Water Boiler Piping
Design a piping system and install boiler which will FORCEOL084 prevent oxygen contamination of boiler water and FORCEOL115 frequent water additions. FORCEOL147 1. There are many possible causes of oxygen FORCEOL189 10.0 contamination such as: a. Addition of excessive make-up water as a result of system leaks. - Page 20 IV: Water Boiler Piping (continued) Figure 11: Recommended Piping for Combination Heating and Cooling (Refrigeration) System 5. If it is required to perform a long term pressure WARNING test of the hydronic system, the boiler should first be isolated from the system to avoid a pressure loss The use of a low water cut-off device, while not due to the escape of air trapped in the boiler.
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Page 21: Indirect Water Heater Piping
V: INDIRECT WATER HEATER PIPING A. CONNECT INDIRECT DOMESTIC WATER Refer to instructions furnished with Indirect Water HEATER PIPING as shown in Figure 12A and 12B. Heater for additional information. Also refer to Figure 10A and 10B. Figure 12A: Indirect Water Heater Piping w/Supply Side Circulator on Circulator Zoned Heating System Figure 12B: Indirect Water Heater Piping w/Supply Side Circulator on Zone Valve Zoned Heating System... -
Page 22: Natural Draft Venting (Chimney)
Long term operation while in this condition may Some jurisdictions require the use of a liner when cause a venting failure and force flue gases into changing fuel types. Some jurisdictions require the living space. If the chimney is to be re-lined the use of a liner even when the same fuel is used. - Page 23 VI: Natural Draft Venting (Chimney) (continued) FIRECLAY TILE LINED CHIMNEY NOT LESS THAN 8" X 8" X 15' THIMBLE NOTE: ALL HORIZONTAL VENT PIPE SHOULD SLOPE UPWARD NOT SLOPE UP LESS THAN ONE INCH IN APPROX. FOUR FEET. 120° AIR GAP DRAFT REGULATOR 10 O'CLOCK 2 O'CLOCK...
- Page 24 VI: Natural Draft Venting (Chimney) (continued) D. STACK TEMPERATURE DANGER 1. The temperature of the flue gases has a significant Any signs of condensate seepage at the base of effect on the amount of draft created in a vertical the chimney shall be inspected immediately. The chimney as well as the propensity to create discoloration may be a sign of chimney damage condensate.
- Page 25 VI: Natural Draft Venting (Chimney) (continued) E. MINIMUM CLEARANCES WARNING See Figure 2A for details regarding clearances to combustibles for the boiler. Remove the baffles if there are any signs of condensation in the chimney or chimney connector. Consult with your local chimney professional for recommendations.
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Page 26: Direct Venting / Air Intake Piping
VII: DIRECT VENTING / AIR INTAKE PIPING A. GENERAL GUIDELINES WARNING 1. Direct Vent system must be installed in accordance with these instructions and applicable provisions of local This venting system must be installed by a building codes. Contact your local fire and building qualified installer (an individual who has been officials on specific requirements for restrictions properly trained) or a licensed installer. - Page 27 Direct Vent Conversion "L" Dimension Kit Part No. (Inch) public walkway. e. Not less than 3 ft (as measured to side of vent FORCEOL147 termination) from an inside corner of an L-shaped 106401-01 8¼ FORCEOL189 structure. f. Not less than 1 ft from the nearest surface of the terminal to a roof soffit.
- Page 28 VII: Direct Venting / Air Intake Piping (continued) D. INSTALLING THE FLEX OIL VENT PIPE FROM THE VENT TERMINATION TO THE BOILER FLUE OUTLET 1. The venting system (vent pipe and all connectors) shall be installed in accordance with the applicable provisions of any local codes, and, in United States, requirements of NFPA 31- Standard for the Installation of Oil-Burning Equipment and NFPA 211 Standard for...
- Page 29 Collar OD (Inch) Vent Pipe Adapter (Inch) Diameter (Inch) (Inch) FORCEOL147 6 to 5 FORCEOL189 NOTE: * The model specific Direct Vent (FDVS) Kit Cartons contain adapters (reducers) (see Table 6) to connect boiler flue outlet collar to vent pipe.
- Page 30 VII: Direct Venting / Air Intake Piping (continued) 7. Apply sealant; firstly, between the stop bead and retainer bead at the end of the vent termination inner pipe; secondly, between the stop bead and retainer bead at the end of the appliance adapter. See Figure 8.
- Page 31 VII: Direct Venting / Air Intake Piping (continued) WARNING DO NOT reduce size of air intake pipe. 3. Remove burner from carton. Secure burner to boiler with mounting hardware included with burner swing door. See Figure 26. 4. Remove knockout for 4" vent pipe collar from burner cover.
- Page 32 VII: Direct Venting / Air Intake Piping (continued) 12. Assemble the vacuum relief valve balance weight onto 14. Install remainder of air intake piping to Direct Vent the gate. Refer to the vacuum relief valve manufacturer’s Termination air intake collar, securing each joint with instructions for details.
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Page 33: Electrical
VIII: ELECTRICAL DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. - Page 37 VIII: Electrical (continued) NOTE: APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO Figures 27 and 28 NOTE: APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO Figure 28 Figure 30: Schematic Wiring Diagrams...
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Page 38: Oil Piping
IX: OIL PIPING A. GENERAL WARNING 1. Use flexible oil line(s) so the burner swing door Under no circumstances can copper with sweat can be opened without disconnecting the oil supply style connectors be used. piping. 2. A supply line fuel oil filter is recommended as a NOTICE minimum for all firing rates but a pleated paper fuel oil filter is recommended for the firing rates below... - Page 39 Ix: Oil Piping (continued) C. TWO PIPE OIL LINES 3. Under no circumstances is a manual shutoff valve to be located on the return line of a two pipe system. 1. For two piped systems, where more lift is required, Accidental closure of the return line will rupture the the two-stage fuel unit is recommended.
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Page 40: System Start-Up
X: SYSTEM START-UP WARNING All boilers equipped with burner swing doors have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed. - Page 41 x: System Start-Up (continued) D. ADJUST CONTROL SETTINGS with burner e. Loosen the two screws securing the rear door, service switch turned “ON”. then swing to the right and down. 1. SET ROOM THERMOSTAT about 10°F below f. Loosen splined nut. room temperature.
- Page 43 x: System Start-Up (continued) 4. Close vent fitting and burner flame should start WARNING immediately after prepurge is completed. Prepurge prevents burner flame until 15 seconds has elapsed Very hot flue gases come out of flame observation after initial power is applied to burner. During port cover hole when boiler is operated with port prepurge the motor and igniter will operate but the cover open.
- Page 44 Beckett AFG Burners H. CHECK FOR CLEAN CUT OFF OF a. FORCEOL084 through FORCEOL147 BURNER. Beckett MB(L1 & L2) Head burners have a fixed 1. AIR IN THE OIL LINE between fuel unit and head which are non-adjustable.
- Page 45 x: System Start-Up (continued) Figure 38: Cad Cell Location 2. VERIFY OIL PRIMARY CONTROL FEATURES using procedures outlined in Instructions furnished with control or instructions as follows: a. GeniSys 7505 Control Features, see Figure 39. The geniSys 7505 is a microprocessor- based control.
- Page 46 x: System Start-Up (continued) vii. Cad Cell Resistance Check: For proper securely in socket. Check gasket around operation it is important that the cad perimeter of ignitor lid for proper seal. If cell resistance is below 1600 ohms. During gasket is missing or damaged, replace gasket. a normal call for heat, the cad cell leads Room light can effect cad cell resistance.
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Page 47: Operating
XI: OPERATING IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWINg CONDITIONS IS TRUE: •... -
Page 48: Maintenance & Service Instructions
Model No. possible, using a high-pressure water stream. Month year o. Refill the system with fresh water. FORCEOL084 0.20 3. Add appropriate boiler water treatment compounds FORCEOL115 0.20 as recommended by your qualified water treatment FORCEOL147 0.25 company. FORCEOL189 0.30... - Page 49 xII: Maintenance and Service Instructions (continued) C. ATTENTION TO BOILER WHILE NOT IN 3. Always keep the manual fuel supply valve shut off OPERATION if the burner is shut down for an extended period of time. NOTICE 4. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions If boiler is not used during winter time, it must be outlined in Section X, System Start-Up, Paragraphs...
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Page 50: Boiler Cleaning
XIII: BOILER CLEANING WARNING All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. - Page 51 xIII: Boiler Cleaning (continued) Figure 40: Cleaning of Boiler Flueways WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result 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 throughout the heating season for any obstructions.
- Page 52 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
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Page 53: Trouble Shooting
XIV: TROUBLESHOOTING A. COMBUSTION 6. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller 1. NOZZLES — Although the nozzle is a relatively amounts will cause excessive wear on the pump, inexpensive device, its function is critical to the but more importantly water doesn’t burn. - Page 54 xIV: Troubleshooting (continued) B. OIL PRIMARY CONTROL (Oil Primary) d. Airflow too high. 1. Burner (Oil Primary) will not come on. e. Ignitor module defective. a. No power to Oil Primary. f. CAD cell defective. b. Oil Primary is in lockout or restricted mode. g.
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Page 55: Repair Parts
XV: REPAIR PARTS All FORCE™ Repair Parts may be obtained by contacting your local Ferguson branch. - Page 57 Repair Parts (continued) Item Description Part No. FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189 1. BARE BOILER ASSEMBLy Cast Iron Section Assembly, 2 Section 103071-02 Cast Iron Section Assembly, 3 Section 103071-03 Cast Iron Section Assembly, 4 Section 103071-04 Spanner Bar Assembly w/Threaded Inserts, Painted, w/Hardware Installed (Includes Items 1C, 1D, 1E and 1F - Qty 1 ea.) 1-1/4"...
- Page 59 Repair Parts (continued) Item Description Part No. FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189 2. JACKET ASSEMBLy Complete Jacket Kit 106443-02 Complete Jacket Kit 106443-03 Complete Jacket Kit 106443-04...
- Page 61 Repair Parts (continued) Item Description Part No. FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189 3. WATER BOILERS - TRIM AND CONTROLS Beckett AFG Oil Burner w/Gasket: FORCEOL084 Spec No. NY2802 102415-01 FORCEOL115 Spec No. NY2803 102415-02 FORCEOL147 Spec No. NY2804 102415-03 FORCEOL189 Spec No. NY2805...
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Page 63: Natural Draft Applications
NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Boiler Model FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189 Air Tube Combination AFG70MQASN AFG70MPASN AFG70MMAQN AFG70MLASN Beckett's Spec. No. - Page 65 BECKETT Nx OIL BURNER PART NOS. FOR FORCEOL SERIES BOILERS DIRECT VENT APPLICATIONS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. FORCEOL147 FORCEOL189 Item Part Description...
- Page 66 Repair Parts (continued) Item No. Description Part No. FORCEOL147 FORCEOL189 4. DIRECT VENT KITS AND PARTS Direct Vent Conversion Kit 106401-01 Adapter, Appliance, FDVS, 5-6 100234-02 Clamp, 6" Appliance, FDVS-6, Half 100235-02 Not Shown Assy., Cover Sleeve, FDVS-5 100236-02 Assy., Cover Ring, FDVS-5...
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Page 68: Appendix B Low Water Cut Off
aPPEndIx B: 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). Only use connections specifically identified for Low Water Cut Off. In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions. minimum When connection must have a... - Page 69 Appendix B: Low Water Cut-off (LWCO) on Hot Water Boilers (continued) How to Test A 24 VAC LWCO is used primarily for gas fired boilers where a 24 volt control circuit exists within the Shut off fuel supply. Lower water level until water boiler.