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WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
– Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
– WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch.
• Immediately call your gas supplier. Follow the supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
– Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Tested &
Portland
Listed By
Oregon USA
US
OMNI-Test Laboratories, Inc.
0117CB037S
OUTDOOR COAL FURNACE
OWNER'S MANUAL
FORGE 1500
FORGE 3500
SAVE THESE
INSTRUCTIONS
(p/n 9000578 - REV. A) - 12-DEC-2017
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Table of Contents
Related Manuals for Central Boiler FORGE 1500
Summary of Contents for Central Boiler FORGE 1500
- Page 1 OUTDOOR COAL FURNACE OWNER’S MANUAL FORGE 1500 FORGE 3500 WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. – Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
- Page 2 Central Boiler, Inc. • 20502 160th Street • Greenbush, MN 56726 www.CentralBoiler.com The Forge outdoor hydronic heater by Central Boiler is listed by OMNI-Test Laboratories to the applicable portions of the following standards: UL 2523-2013 Solid Fuel-Fired Hydronic Heating Appliances, Water Heaters, and Boilers, CAN/CSA-B366.1-11 (R2015) Solid Fuel-Fired Central Heating Appliance.
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Page 3: Table Of Contents
Central Boiler Furnace Installation - Connecting to Your Existing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 dealer. -
Page 4: Central Boiler Online Resources
Enter CentralBoiler.com in your browser or scan the code using any QR code reader app on your smartphone to access Central Boiler's library of information to help with installation, operation and maintenance of your Central Boiler outdoor furnace. Detailed Furnace Installation Variations - http://www.CentralBoiler.com - go to Explore > Furnace Installation View and/or download PDFs to assist in installation of your outdoor furnace. -
Page 5: Terms And Symbols
Be sure to follow all instructions and related precautions as they are meant for your safety and protection. Store this manual in a readily accessible location for future reference. Forge 1500 Measurements 135 124 135 Forge 3500 Measurements 160 130 163 - Measurement (F) is from firebox door to chimney inspection cover. -
Page 6: Glossary And Industry Terminology
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Glossary and Industry Terminology Several terms and words used throughout this owner's manual are unique to the coal-burning industry: Clinker A mass of fused ash. A clinker is typically very hard and may have the appearance of lava rock or melted glass (see About Clinkers section for more). -
Page 7: Foundation
Do not use any combustible caused by an occurrence outside the outdoor furnace enclosure. Foundation may consist of concrete, crushed materials for the foundation. rock, or patio blocks. © 2016 Central Boiler... -
Page 8: Access To Ports On Outdoor Furnace
NOTE: The Installation Guide provides more information on pump selection. For even more detailed information, see the Hydronic Component Selection Guide (p/n 2482), available from your Central Boiler dealer. Forge 1500 Models – 1-Pump Configuration* Forge 3500 Models – 2-Pump Configuration* 2 - Pump Parts Lists* For 3/4"... -
Page 9: Ground Rod Kit
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Ground Rod Kit The outdoor furnace must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction or, in absence of such requirements, with the National Electrical Code, ANSI/NFPA 70 and/or the Canadian Electrical Code Part 1, CSA C22.1 Electrical Code. - Page 10 Any electrical installation should be done by a qualified installer NOTE: A certified electrician must in accordance with applicable do the electrical installation. © 2014 Central Boiler codes. Remote Thermal Storage Installation Connecting to Remote Thermal Storage Tank To Thermal...
- Page 11 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL OUTDOOR COAL FURNACE BEST BURN PRACTICES Read and follow all operating instructions supplied by the manufacturer. FUEL USED: Only those listed fuels recommended by the manufacturer of your unit. Never use the following: trash, plastics, gasoline, rubber, naphtha, household garbage, material treated with petroleum products (particle board, railroad ties and pressure treated wood), leaves, paper products, and...
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Page 12: Chimney Recommendations
NOTE: For chimney extensions or chimney replacement, use only In higher populated areas, extend the chimney to a height genuine Central Boiler chimney components. Parts are available above the roofs of surrounding buildings. Use Central from an authorized Central Boiler dealer. -
Page 13: Important Precautionary Information
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Important Precautionary Information Be sure to read carefully and understand these precautions before, during and after the installation, operation and maintenance of the furnace. NOTE: All operations must be in accordance with local and state codes which may differ from the information in this manual. - Page 14 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL NOTE: Do not use chemicals or fluids to start the fire. Use kindling and seasoned wood to start an initial fire. DO NOT touch the outdoor furnace during operation. NOTE: The use of wood in this outdoor furnace, except for the purpose of igniting the coal, is prohibited by law.
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Page 15: Helpful Tips
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Helpful Tips • Unlike anthracite, which is fairly consistent in its composition, bituminous coal can vary greatly not just from one mine to another, but from different portions of the same mine. Whenever getting a new load of coal, pay close attention to the outdoor furnace when first burning it to determine whether or not adjustments can be made to the outdoor furnace settings. -
Page 16: Understanding Coal
When clean, anthracite will not typically make marks if rubbed on paper. If burning anthracite in the Central Boiler Forge Outdoor Coal Furnace, nut sized coal is preferred. Cleaned anthracite has a shiny black appearance similar to volcanic glass. -
Page 17: Bituminous
Forge Because of this, lignite coal is not recommended for use in the Central Boiler Outdoor Coal Furnace. Forge Outdoor Coal Furnace. -
Page 18: Operating Instructions
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Operating Instructions FireStar Combustion Controller Refer to the FireStar Operator's Manual provided with your outdoor furnace for information about the controller. Firebox Door Opening Procedure This firebox door opening procedure should be followed whenever the firebox door is opened regardless of coal type. -
Page 19: Maintaining The Ash Bed
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL CAUTION Never keep the firebox door open longer than necessary. If at any time smoke or flames start increasing to the point where they are billowing out the door, quickly shut the firebox door and wait a few minutes before repeating the door opening procedure. Maintaining the Ash Bed If burning bituminous, it is very important to establish and maintain a 3-4"... - Page 20 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Establish Initial Ash Bed Disconnect the heat load draw by turning off the pump(s). Set the under and over air levels on the FireStar Combustion Controller. See the FireStar Operating Manual for more information. NOTE: If burning anthracite, the over air setting should be set to 0.
- Page 21 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Grasp the shaker grate handle and quickly shake the grates three to four times to sift out some of the ash while not losing the hot coals through the grates. Using a shovel, add a single layer of anthracite over the glowing coals. Make sure the layer of anthracite covers the entire grate area.
- Page 22 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Close the firebox door and press the Reset button. NOTE: Pressing the Reset button will decrease the under air slightly while increasing the over air for an adjustable duration of time (see FireStar Operating Manual). This allows more air into the firebox to aid in the proper combustion of volatiles.
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Page 23: Adding Heat Load
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL 15. Grasp the shaker grate handle and quickly shake the grates three to four times to sift out some of the ash while not losing the hot coals through the grates. 16. After the water temperature is above 150˚F (66˚C), proceed to Adding Heat Load. - Page 24 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL The recommended method is to develop a loading schedule that corresponds to when there is a call for heat. This will allow the outdoor furnace to run for an extended period of time after being loaded with new coal and allow time for the volatiles to be burned off.
- Page 25 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Using a shovel, add the desired amount of coal evenly across the coal bed. Don't fill with anthracite coal higher than the bottom of the firebox door sill. Standing off to the side away from the firebox door opening, grasp the shaker grate handle and quickly open and close the grates a couple of times.
- Page 26 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Full Bed Coverage Glowing coals New bituminous load This method is ideal for small and frequent loading. For this method, the coals are first raked even and flat. A thin layer of bituminous coal is added over the whole coal bed, leaving a small area of glowing coals toward the back of the firebox exposed.
- Page 27 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Twin Peaks Glowing coals New bituminous load The hot coals are pushed toward the back of the firebox to form a small hill. The remaining hot coals are raked level. Bituminous coal is added in two small strips running from the base of the small hill to the front of the firebox.
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Page 28: About Clinkers
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Strategic Scoop Placement Method #2 Glowing coals New bituminous load If the coal bed contains a fused, glowing mass of coal, or if there are still large amounts of unburned coal, this method allows you to add coal without disturbing the larger chunks. -
Page 29: Dump To Empty Procedure
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Clinker formation depends on many factors that range from impurities to how the outdoor furnace is operated. Coal, especially bituminous, contains a number of different impurities, mostly minerals and chemicals that are contained within the coal. Over time, these will fuse together from the intense heat and eventually form clinkers. -
Page 30: Ash Cleanout
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL NOTE: For the dump and reload procedure, you will need some pieces of very dry wood at least 24 inches long but short enough to fit inside the firebox. Ideally, the wood should be split with a rough cross-sectional area between 1.5"... - Page 31 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL If the combustion fan is not running, press the Purge button. Wait for the Purge cycle to run its course, allowing the combustion fan to run for a few minutes, and observe the chimney until little or no smoke is being emitted.
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Page 32: Maintenance
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Maintenance PREVENTIVE MAINTENANCE SCHEDULE Regular maintenance and inspections can SERVICE INTERVAL help extend the life of your outdoor furnace and prevent high-cost repairs. This table is meant to serve as a general guideline until you become acquainted with how the outdoor furnace operates with your specific application. -
Page 33: Control Locations
Light Switch ROUTINE MAINTENANCE CAUTION Use only genuine Central Boiler Parts and Accessories if it ever becomes necessary to replace any component of the outdoor furnace. Routine inspections and maintenance are essential to the proper operation and longevity of the outdoor furnace. The items indicated in the preventive maintenance schedule are intended to serve as a guideline. - Page 34 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Creosote - Formation and Need for Removal. When wood is burned slowly, it produces tar and other organic vapors, which combine with expelled moisture to form creosote. The creosote vapors condense in the relatively cool chimney flue of a slow-burning fire.
- Page 35 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Each time ash is cleaned out, inspect the firebox door seal and/or covers to make sure they are sealing properly. Every other day (or as needed), completely scrape the face of the firebox door frame where the door seal contacts.
- Page 36 Inspection Cover 3-6. Ripple Top and HeatLock Baffle © 2015 Central Boiler NOTE: The Ripple Top and HeatLock Baffle require minimal maintenance; however, if any heavy deposits or soot have accumulated, allow the outdoor furnace to cool down and then remove with a brush.
- Page 37 Furnace shown for illustration purpose only; actual furnace will vary. ©2016 Central Boiler CAUTION Remove as much ash as possible as ash can trap moisture which can greatly increase the chance for corrosion.
- Page 38 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL CAUTION If ash and clinkers are disposed of by burial in soil or otherwise locally dispersed, they should be retained in the closed container until thoroughly cooled. Other waste shall not be placed in this container. When removing ash or clinkers, be careful not to spill any outside of the noncombustible container.
- Page 39 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Do not proceed without testing that power is disconnected. Remove the outer airbox cover; then open the airbox cover. Inspect the combustion air fan inlet screen and fan wheel and clean if necessary. Make sure the air intake is clean and not obstructed.
- Page 40 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL 3-10. Over/Under Air Elbows Disconnect the electrical power to the outdoor furnace at the main power source. Do not proceed without testing that power is disconnected. Make sure the power cannot be reconnected while servicing the solenoids (i.e., use lock out, tag out). Remove the outer airbox cover;...
- Page 41 Door Frame Ash Collection Chamber Firebox Chimney Tee Ash Collection Chamber © 2016 Central Boiler NOTE: Refer to the illustration and clean the areas identified in the order shown. For each area in the illustration, refer to the following corresponding section.
- Page 42 Use the mark as a reference when removing ash. CAUTION Take care not to push ash or debris into the over/under air outlets when removing ash. Furnace shown for illustration purpose only; actual furnace will vary. ©2016 Central Boiler...
- Page 43 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL 3. Firebox Using a shovel, remove as much coal and ash as possible. Use the Dump to Empty Procedure to dump the remaining coals and ash into the ash collection chamber. If necessary, remove ash and coal from the ash colleciton chamber to make room.
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Page 44: Water Quality And Maintenance
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL WATER QUALITY AND MAINTENANCE An important part of outdoor furnace maintenance is controlling the quality of the water in the outdoor furnace. Water Test Kits and Test Results DATE pH LEVEL NITRITE LEVEL Record the results of pH and nitrite level tests in the table above. -
Page 45: Testing Supply Water
Corrosion Inhibitor Plus™ and Initial Treatment Central Boiler Corrosion Inhibitor Plus™ (p/n 1650) gives optimum protection when it is used to initially treat the water and is then maintained at proper levels. -
Page 46: Testing Treated Water In The Outdoor Furnace
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL NOTE: If the system has a larger than normal water capacity, more Corrosion Inhibitor Plus™ should be added at a recommended rate of one unit per 180 gallons (681 liters) of water. Add the recommended amount of Corrosion Inhibitor Plus™ through the vent pipe at the top of the outdoor furnace. -
Page 47: System Maintenance
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL NOTE: Always hold the dropper in a vertical position to ensure proper droplet size. If the nitrite level is not at least 20 drops by nitrite test, add 1/4 unit of Corrosion Inhibitor Plus™ (p/n 1650); then circulate water for 24 hours and repeat procedure, as needed, to achieve a nitrite level of at least 20 drops by nitrite test. -
Page 48: Post Heating Season Maintenance
Rotate the wand in a circle to flush thoroughly. Flush top of firebox and bottom of water jacket beneath firebox using wand placed in vent. Drain location © 2016 Central Boiler... - Page 49 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL CAUTION Completely clean out the firebox before draining water from the outdoor furnace. Close the drain valve securely and replace the cap on drain after flushing the outdoor furnace. Add Corrosion Inhibitor Plus™. Fill the outdoor furnace following the procedure in Water Quality and Maintenance.
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Page 50: Serviceable Items
NOTE: If any of these items are under warranty, remember that the warranty covers only the cost of the replacement part. Labor is not covered. NOTE: Use only genuine Central Boiler parts and accessories if it ever becomes necessary to replace any component on the outdoor furnace. -
Page 51: Firebox Door Seal
When the seal has been pressed into the groove all the way around the ©2015 Central Boiler firebox door, cut the end of the rope about one inch longer than required and press it tightly against the beginning end of the rope. -
Page 52: Ash Removal Door Seal
This mark must extend, with no gaps, around the entire perimeter of the firebox door seal. If needed, adjust the hinges and latch assembly. ©2014 Central Boiler CAUTION The firebox door seal will be damaged or destroyed if it is not installed properly. -
Page 53: Thermocouple
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Ash Removal Door When the seal has been pressed into the groove all the way around the door, cut the end of the rope about one inch longer than required and press it tightly against the beginning end of the rope. Close the ash collection chamber door and securely latch. -
Page 54: Troubleshooting
Water Quality and Maintenance section. If adding water does not correct the problem, contact your Central Boiler dealer. 10. Low water temperature for too long a period of time - The display on the controller will indicate Fire Out and the controller will shut down the furnace if the water temperature has been too low for too long. - Page 55 If no exhaust comes out, chimney might still be drafting poorly at times. © 2015 Central Boiler • If a spark arrestor is being used, make sure it is clean and unobstructed. • Objects like buildings and trees in close proximity or nearby terrain (e.g., hills, valleys, etc.) can adversely affect air flow in the chimney.
- Page 56 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Coal bed not large enough to ignite new fuel - An adequate bed of glowing coals is required to ignite new fuel. To re-establish a bed of coals, try to add small amounts of fuel until a thick bed of glowing coals is established before adding a full load.
- Page 57 12. Poor water quality - Water with high amounts of solids, sand or dirt can create deposits inside the wall of heat exchanger components, reducing the amount of heat output. If this condition is suspected, contact your Central Boiler dealer. 13. New construction with radiant in-floor heat - Bringing a cold concrete slab up to temperature the first time will take a considerable amount of time and wood;...
- Page 58 © 2014 Central Boiler Make sure the pump motor is installed in a horizontal position. The junction box must not be located below the pump motor. If necessary, remove the four screws...
- Page 59 FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL Water will not circulate - If the system has been drained and refilled, or if the system has been opened for any reason (e.g., replacement of pump, adding heat exchangers, repairing a leak), the system must be purged (see Initial Start-up Procedures).
- Page 60 Some, but not all, causes of corrosion are listed below with possible solutions. If you are unsure how to proceed, contact your Central Boiler dealer. Water temperature is too low - If the heat load in the system is too large, the water in the system will not reach high enough temperatures to dry the firebox and corrosion can occur.
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Page 61: General Information
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL GENERAL INFORMATION Coal Sizes Anthracite inches Stove 2-7/16 1-5/8 Chestnut 1-5/8 13/16 13/16 9/16 Buckwheat 9/16 5/16 Rice 5/16 3/16 Barley 3/16 3/32 Bituminous Sieve Size (inches) Sieve Size (mm) THROUGH RETAINED THROUGH RETAINED Run of Mine Lump... -
Page 62: Decals
Manual. l’ensemble des législations et any questions, contact your AVIS served or not served, © 2016 Central Boiler p/n 7000498 • DO NOT allow others to install réglementations applicables. dealer. whichever is higher. Pour réarmer le disjoncteur, or operate furnace without first •... -
Page 63: Wiring Diagram
FORGE OUTDOOR COAL FURNACE • OWNER'S MANUAL WIRING DIAGRAM... - Page 64 ©2017 Central Boiler Printed in U.S.A. (p/n 9000578 - REV. A) • 18-DEC-2017...