1. Manuals
  2. Brands
  3. Ferguson Manuals
  4. Boiler
  5. FORCE02
  6. Installation, operating and service instructions

Ferguson FORCE02 Installation, Operating And Service Instructions

Cast iron gas-fired boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
INSTALLATION, OPERATING
SERVICE INSTRUCTIONS
CAST IRON GAS-FIRED BOILER
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
FORCE
Heating Contractor
Address
105941-01 - 11/14
AND
FORCE™ SERIES
Boiler Serial Number
9700609
Installation Date
Phone Number

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the FORCE02 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Ferguson FORCE02

  • Page 1 INSTALLATION, OPERATING SERVICE INSTRUCTIONS FORCE™ SERIES CAST IRON GAS-FIRED 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 Boiler Serial Number Installation Date FORCE...

  • Page 2: Table Of Contents

    V. Venting ..........11 XI. Repair Parts ........26 VI. Electrical ..........13 Table 1A: Ratings Force Gas Ratings Boiler Model Input (MBH) DOE Heating Capacity (MBH) Net AHRI Rating Water (MBH) AFUE (%) FORCE02 37.5 FORCE03 FORCE04 FORCE05 FORCE06 FORCE07 FORCE08 FORCE09 FORCE10 Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15.
  • Page 3 Table 1B: Dimensions and Connections Supply NPT Return NPT Relief Valve Drain Boiler Model Vent (inch) Gas NPT (inch) (inch) (inch) NPT (inch) NPT (inch) FORCE02 1¼ 1¼ ½ ¾ ¾ FORCE03 1¼ 1¼ ½ ¾ ¾ FORCE04 1¼ 1¼...
  • Page 4 Figure 1: Minimum Clearance to Combustible Materials...

  • Page 5: Pre-Installation

    I. Pre-Installation WARNING WARNING Adequate combustion and ventilation air must be Carefully read all instructions before installing provided to assure proper combustion. boiler. Failure to follow all instructions in proper order can cause personal injury or death. The following guideline is based on the National Fuel Gas Code, ANSI Z223.1/NFPA 54.

  • Page 6: Unpack Boiler

    I. Pre-Installation (continued) a. Direct communication with outdoors. Minimum and rodents. Louvers and grilles must be fixed in free area of 1 square inch per 4,000 Btu per hour open position or interlocked with equipment to open input of all equipment in space. automatically before burner operation.

  • Page 7: Water Piping And Trim

    III. Water Piping and Trim appropriate valves to prevent chilled medium from WARNING entering boiler. See Figure 3. Failure to properly pipe boiler may result in If boiler is connected to heating coils located in improper operation and damage to boiler or air handling units where they may be exposed to building.

  • Page 10: Gas Piping

    IV. Gas Piping Size gas piping. Design system to provide adequate gas 4. All above ground gas piping upstream from manual supply to boiler. Consider these factors: shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas 1.

  • Page 11: Venting

    V. Venting Install vent system in accordance with "Venting of Equipment" of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or applicable provisions of local building codes. Install any of the following for this Force Series Category I, draft hood equipped appliance: 1.
  • Page 12 V. Venting (continued) a. Seal any unused openings in the common venting Install Vent Connector system. 1. Install vent connector from vent damper outlet to b. Visually inspect the venting system for proper chimney. size and horizontal pitch and determine there is no 2.

  • Page 13: Electrical

    VI. Electrical General. Install wiring and electrically bond boiler to For installations using zone valves provide separate ground in accordance with requirements of authority transformer for zone valve wiring. Consult zone valve having jurisdiction, or in absence of such requirements, manufacturer for assistance.
  • Page 14 VI. Electrical (continued)
  • Page 15 VI. Electrical (continued) Figure 9: Schematic Ladder Diagram...

  • Page 16: System Start-Up And Checkout

    VII. System Start-up and Checkout 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 17 VII. System Start-up and Checkout (continued) CAUTION 11. Test gas piping and connections between Combination Gas Valve and manifold, orifices, and pilot piping for leaks after boiler is operating. Use soap solution or other approved method. Check Gas Input to Boiler 1.
  • Page 18 VII. System Start-up and Checkout (continued) Check Ignition System Safety Shut-off Device. Combustion Chamber Burn-off 1. The mineral wool combustion chamber panels Remove 3-wire plug from gas valve. may contain a cornstarch based binder that must be If burners do not shut down determine cause of burned out at installation to prevent odors during malfunction.

  • Page 19: Operation

    VIII. Operation Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. Electronic Ignition Module See Figure 13 for electronic ignition (EI). Electronic Ignition Modules with LED indicators. Table 2 cross- references the ignition module terminal designations to the ignition terminal numbers in the wiring ladder diagrams.
  • Page 20 VIII. Operation (continued) v. Check the pilot flame. It must be blue, Check the pilot burner operation/ignition steady and envelop the flame sensing rod sequence during ignition cycle: 3/8” to ½”. i. Restore boiler power at circuit breaker or vi. If needed, adjust pilot flame by fuse box.

  • Page 21: Service And Maintenance

    IX. Service and Maintenance 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.
  • Page 22 IX. Service and Maintenance (continued) Figure 15: Operating Instructions...
  • Page 23 IX. 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. Keep boiler area clear and free of combustible materials, gasoline and other flammable vapors and liquids.

  • Page 24: Troubleshooting

    X. Troubleshooting Temperature Limit/LWCO Control Refer to the HydroStat 3200 Installation Instructions and Operating Manual included with these instructions. Electronic Ignition Module (see Figure 16)
  • Page 25 X. Troubleshooting (continued) "CALL FOR HEAT." POWER TO CHECK LINE VOLTAGE POWER, LOW VOLTAGE TRANSFORMER, LIMIT CONTROLLER, THERMOSTAT (CONTROLLER), AND WIRING. ALSO, MODULE? (24 V CHECK AIR PROVING SWITCH ON COMBUSTION AIR BLOWER SYSTEM (IF USED) AND THAT THE VENT DAMPER END SWITCH (IF USED) NOMINAL) IS MADE.

  • Page 26: Repair Parts

    XI. Repair Parts All Force™ Repair Parts may be obtained by contacting your local Ferguson branch. [Quantity] Part Number Description FORCE02 FORCE03 FORCE04 FORCE05 FORCE06 FORCE07 FORCE08 FORCE09 FORCE10 Block Assembly 617190204 617190304 617190404 617190504 617190604 617190704 617190804 617190904 617191004...
  • Page 27 XI. Repair Parts (continued) [Quantity] Part Number Description FORCE02 FORCE03 FORCE04 FORCE05 FORCE06 FORCE07 FORCE08 FORCE09 FORCE10 Base Wrapper 718600211 718600311 718600411 718600511 718600611 718600711 718600811 718600911 718601011 Base Tray 718600291 718600391 718600491 718600591 718600691 718600791 718600891 718600991 718601091 Burner Tray...
  • Page 28 XI. Repair Parts (continued) [Quantity] Part Number Description FORCE02 FORCE03 FORCE04 FORCE05 FORCE06 FORCE07 FORCE08 FORCE09 FORCE10 Gas Valve (Natural 81660145 81660161 Gas), Honeywell Gas Valve (LP 81660146 81660160 Gas), Honeywell Gas Manifold 104810-02 104810-03 104810-04 104810-05 104810-06 104810-07 104810-08...
  • Page 29 XI. Repair Parts (continued) [Quantity] Part Number Description FORCE02 FORCE03 FORCE04 FORCE05 FORCE06 FORCE07 FORCE08 FORCE09 FORCE10 HydroStat 3200 105943-01 Honeywell S8610M 100958-02 EI Module Temp/LWCO 105944-03 Sensor...
  • Page 30 XI. Repair Parts (continued) [Quantity] Part Number Description FORCE02 FORCE03 FORCE04 FORCE05 FORCE06 FORCE07 FORCE08 FORCE09 FORCE10 Complete Jacket 105519-02 105519-03 105519-04 105519-05 105519-06 105519-07 105519-08 105519-09 105519-10 Jacket Horizontal 7041920 Clip (not shown) Jacket Vertical Clip 7041921 (not shown)
  • Page 31 XI. Repair Parts (continued) [Quantity] Part Number Description FORCE02 FORCE03 FORCE04 FORCE05 FORCE06 FORCE07 FORCE08 FORCE09 FORCE10 Temperature/ 100282-04 100282-01 Pressure Gauge 30 PSI Relief Valve 81660319 6C Drain Valve 806603061 6D Vent Damper 102284-01 102284-02 102284-03 102284-04 102284-05 Grundfos UPS 15-...
  • Page 32 XI. Repair Parts (continued) Common Replacement Parts ( All Sizes) Description Part Number HydroStat 3200 105943-01 Temp/LWCO HydroStat Sensor 105944-03 HydroLevel ElectroWell 4" Insulation Length 105310-01 HydroLevel ElectroWell 1" Insulation Length 105203-01 Honeywell S8610M EI Module 100958-01 Flame Rollout Switch 80160044 Blocked Vent Switch 80160157...

This manual is also suitable for:

Force03Force04Force05Force06Force07Force08 ... Show all

Table of Contents