Table of Contents
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Installation, Operating and Service Instructions for
FORCE
Models:
• FORCE02E
• FORCE03E
• FORCE04E
• FORCE05E
• FORCE06E
• FORCE07E
• FORCE08E
• FORCE09E
Manual Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pre-installation . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing Existing Boiler . . . . . . . . . . . . . . . . . 5
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System Start-Up and Checkout . . . . . . . . . . . 17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Before Leaving Jobsite . . . . . . . . . . . . . . . . . . 24
Service and Maintenance . . . . . . . . . . . . . . . . 25
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 31
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
Provide model number and serial number when
seeking information and support.
TO THE CONSUMER:
Retain these instructions for future reference.
Contact heating contractor for all issues and support.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury,
or loss of life. For assistance or additional information, consult a qualified installer, service agency or gas
supplier. Read these instructions carefully before installing.
109444-03 - 12/19
TM
Page
!
WARNING
• Water Boiler
• Cast Iron
• Chimney Vent
• Gas Fired
9700609
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Table of Contents
Related Manuals for Force FORCE02E
Summary of Contents for Force FORCE02E
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Page 1: Table Of Contents
Installation, Operating and Service Instructions for FORCE • Water Boiler • Cast Iron • Chimney Vent • Gas Fired Models: • FORCE02E • FORCE03E • FORCE04E • FORCE05E • FORCE06E • FORCE07E • FORCE08E • FORCE09E Manual Contents Page Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pre-installation . - Page 2 The City of New York requires a Licensed Master Plumber supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has listed the FORCE E Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://licensing .reg .state .ma .us/pubLic/pl_products/pb_product .asp for the latest Approval Code or ask your local Sales Representative.
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Page 3: Specifications
FORCE E Installation, Operating & Service Manual Specifications Table 1A: Ratings Boiler Model Number Input (MBH) DOE Heating Capacity (MBH) AHRI Net Rating (MBH) AFUE FORCE02E 84.0 FORCE03E 84.0 FORCE04E 84.0 FORCE05E 84.0 FORCE06E 84.0 FORCE07E 84.0 FORCE08E 84.0 FORCE09E 84.0... -
Page 4: Pre-Installation
Failure to follow all instructions in proper ANSI Z223.1/NFPA 54, or applicable provisions of order can cause personal injury or death. local building codes. A. FORCE E boiler is Category I, draft hood WARNING equipped appliance with vent damper. Adequate combustion and ventilation air must be provided to assure proper combustion and B. -
Page 5: Removing Existing Boiler
4. Hot water pipes: at least 1/2" from for left side and front jacket panels . combustible material. 2. Closet Installation - Models FORCE02E, B. Provide Combustion and Ventilation Air in FORCE03E, FORCE04E, FORCE05E, accordance with the section "Air for Combustion FORCE06E,FORCE07E, &... - Page 6 Installation, Operating & Service Manual FORCE E Clearances (continued) Model FORCE02E 14" FORCE03E 14" FORCE04E 16" FORCE05E 19" FORCE06E 22" FORCE07E 25" FORCE08E 28" Figure 4-1: Minimum Closet Clearances Model FORCE09E 31" Figure 4-2: Minimum Alcove Clearances Minimum radial clearance around vent pipe and breeching for single-wall metal pipe vent connector. Otherwise, follow vent connector manufacturer's recommended clearances.
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Page 7: Venting
D. Install vent system in accordance with "Venting of Appliances" of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes. The FORCE E boiler is a Category I, draft hood equipped appliance with vent damper. - Page 8 Installation, Operating & Service Manual FORCE E Venting (continued) Draft diverter outlet/vent damper is greater than 4 in. in diameter. 5. Vent pipe should have greatest possible initial rise above draft diverter consistent with head room available and required clearance from adjacent combustible building structure.
- Page 9 FORCE E Installation, Operating & Service Manual Venting (continued) Roof Slope Heights Roof Slope Flat to 6/12 Over 6/12 to 7/12 1.25 Over 7/12 to 8/12 Over 8/12 to 9/12 Over 9/12 to 10/12 Over 10/12 to 11/12 3.25 Over 11/12 to 12/12...
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Page 10: Water Piping
Installation, Operating & Service Manual FORCE E Water Piping D. Connect system supply and return piping to WARNING boiler. Refer to Figures 6-3 and 6-4. Also consult Failure to properly pipe boiler may result in Residential Hydronic Heating Installation and improper operation and damage to boiler or Design I=B=R Guide. - Page 11 FORCE E Installation, Operating & Service Manual Water Piping (continued) 109444-03 - 12/19...
- Page 12 Installation, Operating & Service Manual FORCE E Water Piping (continued) 109444-03 - 12/19...
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Page 13: Gas Piping
FORCE E Installation, Operating & Service Manual Gas Piping A. Size gas piping. Design system to provide adequate gas supply to boiler. Consider these factors: 1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system pressure is ½ psig. Minimum gas valve inlet pressure is listed on rating label. -
Page 14: Electrical
Installation, Operating & Service Manual FORCE E Electrical C. Wire boiler. Boiler is rated for 120 VAC, 60 HZ, WARNING less than 12 A. A separate electrical circuit must Electrical Shock Hazard. Wiring errors can be run from the main electrical service with an cause improper or dangerous operation. - Page 15 FORCE E Installation, Operating & Service Manual Electrical (continued) Figure 8-1: Wiring Connection Diagram 109444-03 - 12/19...
- Page 16 Installation, Operating & Service Manual FORCE E Electrical (continued) Figure 8-2: Schematic Ladder Diagram 109444-03 - 12/19...
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Page 17: System Start-Up And Checkout
FORCE E Installation, Operating & Service Manual System Start-Up and Checkout A. Visual Main Burner Check Attach hose to drain valve located on return piping (see Figure 6-3 and 6-4). Inspect burners for dislodgement during Note-Terminate hose in five gallon bucket, shipment. - Page 18 Installation, Operating & Service Manual FORCE E System Start-Up and Checkout (continued) Figure 9-1: Operating Instructions 109444-03 - 12/19...
- Page 19 FORCE E Installation, Operating & Service Manual System Start-Up and Checkout (continued) Perform limit check 1. Ensure gas to boiler is off 2. Set ROOM THERMOSTAT to lowest setting. 3. If limits are functioning properly (LWCO, flame rollout switch, blocked vent switch, damper), boiler should spark.
- Page 20 Installation, Operating & Service Manual FORCE E System Start-Up and Checkout (continued) J. Check Main Burner Flame (see Figure 9-5) L. Check gas outlet (manifold) pressure 1. NORMAL FLAME: 1. Install manometer on 1/8" outlet pressure tap on gas valve (see Figure 9-2). Use a.
- Page 21 FORCE E Installation, Operating & Service Manual System Start-Up and Checkout (continued) appliance main burners are operating. P. Check ignition system safety shut-off device. After control has finished sparking, remove ignitor/ flame sense wire from control. Burners will shut down.
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Page 22: Operation
Installation, Operating & Service Manual FORCE E Operation A. Temperature Limit/LWCO Control Refer to HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. B. Electronic Ignition Module See Figure 10-1 for electronic ignition (EI). Electronic Ignition Modules with LED indicators. - Page 23 FORCE E Installation, Operating & Service Manual Operation (continued) v. Check pilot flame. It must be blue, h. Check pilot burner operation/ignition steady and envelop flame sensing sequence during ignition cycle: rod 3/8” to ½”. i. Restore boiler power at circuit vi.
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Page 24: Before Leaving Jobsite
Installation, Operating & Service Manual FORCE E Before Leaving Jobsite Before Leaving Jobsite: Boiler and system filled with water Performed gas leak test Checked pilot burner flame Checked main burner flames Checked gas input rate ... -
Page 25: Service And Maintenance
FORCE E Installation, Operating & Service Manual Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen. - Page 26 Installation, Operating & Service Manual FORCE E Service and Maintenance (continued) WARNING Service on this boiler should be undertaken only by trained and skilled personnel from a qualified service agency. Inspections should be performed at intervals specified in this manual. Maintain manual in a legible condition.
- Page 27 FORCE E Installation, Operating & Service Manual Service and Maintenance (continued) D. Clean Main Burners and Firebox. Inspect Temperature/Pressure Gauge 1. Water temperature needle should move with 1. To remove burners for cleaning, changing variation in water temperature. orifices, or repairs: a.
- Page 28 Installation, Operating & Service Manual FORCE E Service and Maintenance (continued) Q. Test Vent Damper Operation Vent damper must be in open position when main burners are operating. R. Test Functionality of LWCO See "Start-up and Checkout - Check LWCO Functionality.
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Page 29: How It Works
Installation, Operating & Service Manual How It Works FORCE E boilers are equipped with Hydrostat 3200 and Honeywell S8610M Ignition module. Hydrostat 3200 contains features such as high limit switch, LWCO and circulator relay. Energy is saved by using a thermal target feature which adjusts boiler target temperature depending on heat required. - Page 30 Installation, Operating & Service Manual FORCE E How It Works (continued) Rear of Boiler (On rear of boiler) 109444-03 - 12/19...
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Page 31: Troubleshooting
FORCE E Installation, Operating & Service Manual Troubleshooting A. Before Troubleshooting When troubleshooting boiler, keep in mind: 1. Troubleshooting should be completed by a professional heating technician. 2. Before seeking technical assistance, the servicing technician should have an electrical meter and gas pressure gauge available for use. - Page 32 Installation, Operating & Service Manual FORCE E Troubleshooting (continued) Start Before troubleshooting, familiarize yourself with the Note: "Call for heat" 24 VAC supply is connected to the 24 V terminal on the control. Startup and Checkout procedures. Turn gas supply off.
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Page 33: Service Parts
FORCE E Installation, Operating & Service Manual Service Parts All FORCE E Series Service Parts may be obtained by contacting your local Ferguson branch. Part Number [Quantity] Key No. Description FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E 109871-02 109871-03... - Page 34 Installation, Operating & Service Manual FORCE E Service Parts (continued) Part Number [Quantity] Description FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Base Wrapper Base Tray Burner Tray Base Side Insulation Base Rear Insulation Base Front Insulation 109941-02 109941-03 109941-04...
- Page 35 FORCE E Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Gas Valve (Natural Gas), 109948-01 [1] Honeywell VR8204C3007 Gas Valve (Natural Gas), 109951-01 [1] Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell...
- Page 36 Installation, Operating & Service Manual FORCE E Service Parts (continued) Part Number [Quantity] Key No. Description FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Hydrostat 3200 LWCO/High Limit 109952-01 [1] Honeywell S8610M EI Module 109945-01 [1] 109444-03 - 12/19...
- Page 37 FORCE E Installation, Operating & Service Manual Service Parts (continued) Part Number [Quantity] Description FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Wrap-around Jacket Panel Not available Jacket Vestibule Panel Rear Discharge Chute 109618-02 109618-03 109618-04 109618-05 109618-06 109618-07 109618-08...
- Page 38 Installation, Operating & Service Manual FORCE E Service Parts (continued) Part Number [Quantity] Description FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Water Manifold 109968-01 [1] Temperature/Pressure Gauge 109966-01 [1] 30 PSI Safety Relief Valve 109964-01 [1] Drain Valve Source Locally (3/4" NPT boiler connection)
- Page 39 FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Power Supply Harness 109963-01 [1] Main Control Harness 109957-01 [1] Ignition Harness 109953-01 [1] Accessories: Part Number [Quantity] Key No. Description FORCE02E FORCE03E FORCE04E FORCE05E FORCE06E FORCE07E FORCE08E FORCE09E Not Shown Boiler Bypass Kit 107795-01 [1] 109444-03 - 12/19...
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Page 40: Appendix
Installation, Operating & Service Manual FORCE E Appendix: Combination Refrigeration/ Heating System A. If boiler is used in connection with refrigeration B. If boiler is connected to heating coils located in systems, boiler must be installed with chilled air handling units where they may be exposed to... - Page 41 FORCE E Installation, Operating & Service Manual Appendix: Low Return Water Temperatures Thermal Shock: Cast iron boilers are very robust. 110oF and below return water temperatures will not cause thermal shock to castings. Condensation is a different matter: Cast iron boilers will tolerate intermittent periods of condensation, but are not designed for extended condensation periods.
- Page 42 Installation, Operating & Service Manual FORCE E Appendix: Low Return Water Temperatures (continued) Primary-Secondary Pumping: This is an improvement over simple by-pass piping to reduce condensation. Again this is a fixed system. It can not adapt to variations in temperature and flow.
- Page 43 FORCE E Installation, Operating & Service Manual 109444-03 - 12/19...
- Page 44 Installation, Operating & Service Manual FORCE E 109444-03 - 12/19...
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