PROSELECT FORCESTM SERIES INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS Pdf Download (2024)

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Page 4: Table Of Contents Page 5: Specifications Page 6: Pre-Installation Page 8: Venting Page 10: Gas Piping Page 11: System Piping Page 14: Indirect Water Heater Piping Page 15: Electrical Page 20: System Start-Up Page 25: Service Instructions Page 29: Troubleshooting Page 33: Repair Parts Page 42: Appendix A - Tapping Locations References
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Table of Contents

  • Table of Contents

  • Product Description

  • Specifications

  • Pre-Installation

  • Locating the Boiler

  • Venting

  • Gas Piping

  • System Piping

  • Indirect Water Heater Piping

  • Electrical

  • System Start-Up

  • Service Instructions

  • Troubleshooting

  • Repair Parts

  • Appendix A - Tapping Locations

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INSTALLATION, OPERATING

SERVICE INSTRUCTIONS

FORCESTM™ SERIES

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

Address

106324-04 - 4/18

AND

GAS BOILER

Boiler Serial Number

Installation Date

Phone Number

Price - $5.00

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PROSELECT FORCESTM SERIES INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS Pdf Download (2)

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Summary of Contents for ProSelect FORCESTM Series

  • Page 1 INSTALLATION, OPERATING 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 Boiler Serial Number Installation Date FORCESTEAM0 _ Heating Contractor...
  • Page 2 WARNINGS FOR THE HOMEOWNER FOLLOW ALL INSTRUCTIONS and warnings DO NOT BLOCK AIR FLOW into or around the printed in this manual and posted on the boiler. boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire. INSPECT THE BOILER ANNUALLY.
  • Page 3 WARNINGS FOR THE INSTALLER READ THIS ENTIRE MANUAL before attempting INSTALL ALL GUARDS, cover plates, and installation, start-up, or service. Improper enclosures before operating the boiler. installation, adjustment, alteration, service, SIZE THE BOILER PROPERLY relative to the or maintenance may cause serious property design heat load or, if using domestic hot water damage, personal injury, or death.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Product Description..................Specifications.................... III. Pre-Installation................... Locating the Boiler..................Air for Combustion & Ventilation..............Venting....................... VII. Gas Piping....................10 VIII. System Piping.................... 11 Indirect Water Heater Piping..............14 Electrical....................15 System Start-Up..................20 XII. Service Instructions................... 25 XIII. Troubleshooting..................29 XIV.

  • Page 5: Specifications

    II. Specifications FIGURE 1: FORCESTM BOILERS - GENERAL CONFIGURATION TABLE 1: FORCESTM SPECIFICATIONS Recommended Min. Water Volume Approx. Dimensions (in inches) Round (Gal.) Shipping Boiler Model Chimney Size Conn. Weight Steam (Diameter x Height) (NPT) Lbs. Boiler FORCESTM03 12¾ 4" x 15 ft. FORCESTM04 5"...

  • Page 6: Pre-Installation

    I. Pre-Installation 1) Safe,reliableoperationofthisboilerdependsuponinstallationbyaprofessionalheatingcontractorinstrictaccordance withthismanualandtherequirementsoftheauthorityhavingjurisdiction. • Intheabsenceofanauthorityhavingjurisdiction,installationmustbeinaccordancewiththismanualandthe National Fuel Gas Code,ANSIZ223.1/NFPA54. • Whererequiredbytheauthorityhavingjurisdiction,thisinstallationmustconformtotheStandard for Controls and Safety Devices for Automatically Fired Boilers(ANSI/ASMECSD-1). Warning This Product Must be Installed By A Licensed Plumber Or Gas Fitter when Installed Within The Commonwealth Of Massachusetts 2) Makesurethataproperlysizedchimneyisavailablewhichisingoodcondition.Consulttheauthorityhaving jurisdiction,PartVIofthismanual,andtheNational Fuel Gas Codeforadditionalinformationonventingrequirements.

  • IV. Locating the Boiler (continued) FIGURE 2: FORCESTM BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS. 3) Theboilermustbeinstalledonahardlevelsurface. 4) Donotinstallthisboilerinalocationwheregasolineorotherflammablevaporsorliquidswillbestoredorused.Donot installthisboilerinanareawherelargeamountsofairbornedustwillbepresent,suchasaworkshop. 5) Theboilershouldbelocatedasclosetothechimneyaspossible. 6) Donotinstallthisboilerdirectlyonasurfacethatmaygetwet.Raisetheboileronapad. V. Air for Combustion & Ventilation Sufficientfreshairmustbesuppliedforcombustion,ventilationandfluegasdilution.Provisionsforcombustion,ventilationand fluegasdilutionairforgasutilizationequipmentventedbynaturaldraftmustbemadeinaccordancewithlocalbuildingcodesor, inabsenceofsuchcodes,inaccordancewith“AirforCombustionandVentilation”oftheNational Fuel Gas Code,ANSIZ223.1/ NFPA54.

  • Page 8: Venting

    VI. Venting Ventinstallationmustbeinaccordancewithlocalbuildingcodes,orthelocalauthorityhavingjurisdiction,ortheNational Fuel Gas Code,ANSIZ223.1/NFPA54. 1. AtypicalventinstallationisillustratedbyFigure3.Thecomponentsofventinstallationaretheventdamper(ifused), ventconnectorandchimney. 2. Installventdamper(seeFigure4)asfollows: a) Openventdampercartonandremoveinstallationinstructions.Readtheinstructionsthoroughlybeforeproceeding. Verifythatventdamperissamesizeasdraftdiverteroutlet.SeeFigure1.Unpackventdampercarefully.Do not force closed damper blade. Forcingventdamperclosedmayresultindamagedgeartrainandvoidwarranty. b) Ventdamperisfactoryshippedhavingapproximately¾”diameterholeintheventdamperblade,whichmust be left openforboilersequippedwithstandingpilot,andshouldbepluggedonboilerswithanintermittentpilotsystem, usingtheplugsuppliedwiththedamper. Mounttheventdamperonthefluecollarwithoutmodificationtoeitherandsecurewithsheetmetalscrews.Make surescrewsdonotinterferewithdamperbladeoperation.Ventdamperbladepositionindicatormustbevisibleto users. c) Thedamperwireharnessisshippedwiredintotheboilerjunctionbox.Plugthelooseendofthisharnessintothe damperandsecuretheflexibleconduittothedamperusingaconnectornutprovided. d) Installventconnectorpipeandventfittingsfromventdamperoutlettochimneyorgasvent.Securewithsheetmetal screwsandsupportasrequired. 3. GasVentTermination Gasventslocatednotlessthan8ft.(24m)fromaverticalwallorsimilarobstructionshallterminateabovetheroofin accordancewithFigure5andTable2. FIGURE 3: FORCESTM BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS 106324-04 - 4/18...
  • Page 9 VI. Venting (continued) FIGURE 4: VENT DAMPER INSTALLATION DETAILS Lowest discharge opening TABLE 2: ROOF SLOPE HEIGHTS Listed Roof Slope H (minimum) Flat to 6/12 0.30 Listed Over 6/12 to 7/12 1.25 0.38 gas vent Over 7/12 to 8/12 0.46 Over 8/12 to 9/12 0.61 Over 9/12 to 10/12...

  • Page 10: Gas Piping

    VII. Gas Piping Gaspipingtotheboilermustbesizedtodeliveradequategasfortheboilertofireatthenameplateinputatalinepressure betweentheminimumandmaximumvaluesshownontheratingplate.Formoreinformationongaslinesizing,consultthe utilityorChapter2oftheNational Fuel Gas Code. Figure6showstypicalgaspipingconnectiontotheFORCESTMboiler.Asedimenttrapmustbeinstalledupstreamof allgascontrols.Installamanualshut-offvalveoutsidethejacketandgroundjointunionasshown. Theboileranditsgasconnectionmustbeleaktestedbeforeplacingtheboilerinoperation.Whendoingthis,theboiler anditsindividualshut-offmustbedisconnectedfromtherestofthesystemduringanypressuretestingofthatsystemat pressuresinexcessof1/2psi.Whenpressuretestingthegassystematpressuresof1/2psiorless,isolatetheboilerfromthe gassupplysystembyclosingitsindividualmanualshut-offvalve. *StateofMassachusettsRequiresManual Shut-offValvetobe“T”HandleType FIGURE 6: GAS CONNECTION TO BOILER 106324-04 - 4/18...

  • Page 11: System Piping

    VIII. System Piping CAUTION • INSTALLBOILERSOTHATTHEGASIGNITIONSYSTEMCOMPONENTSAREPROTECTED FROMWATER(DRIPPING,SPRAYING,RAIN,ETC.)DURINGAPPLIANCEOPERATIONANDSERVICE (CIRCULATORREPLACEMENT,ETC.). • OPERATIONOFTHISBOILERINASYSTEMHAVINGSIGNIFICANTAMOUNTSOFDISSOLVED OXYGENCANCAUSESEVEREHEATEXCHANGERCORROSIONDAMAGE. General Piping Notes Figure7showsrecommendednearboilerpipingformostcommontypesofgravityreturnsteamsystems.Additional informationonsteamsystemdesignmaybefoundinInstallation Guide for Residential Hydronic Heating Systems(Pub. #200). Oneoftheprimarypurposesofthisnearboilerpipingistoseparatetinywaterdropletsfromthesteamexitingtheboiler sothat“dry”steamissenttothesystem.Ifthenearboilerpipingisnotcorrect,wetsteamwillenterthesystemandthe followingproblemsmayoccur: • Short cycling on low water • BoilerorsystemFlooding • Hammering • Failuretoheatoneormoreradiators AvoidthethreecommonpipingmistakesshowninFigure8.Thisapplieseveniftheexistingboilerhasoneofthepiping mistakesshowninFigure8andappearstobeworking.Iftwoormoresteammainsmustbeconnectedtotheboiler,connecta separatetake-offforeachmainintotheheaderbetweentheriser(s)andequalizer.Alsonotethefollowingpoints: 1) Asizereductionmustbemadetoconnecttheheadertotheequalizer.Thisreductionmustbemadeintheequalizerline.
  • Page 12 VIII. System Piping (continued) Piping Installation 1) Removepartsbagfromboilercrate. 2) Installsafetyvalve(spindlemustbeinverticalposition)intotappingonboilerleftside(seeFigure1)usingthe3/4”NPT nippleandelbowsupplied. 3) Pipethedischargeofthesafetyreliefvalvetoalocationwherewaterorsteamwillnotcreateahazardorcauseproperty damageifthevalveopens.Theendofthedischargepipemustterminateinanunthreadedpipe.Ifthesafetyvalve dischargeisnotpipedtoadrainitmustterminateatleast6inchesabovethefloor.Theterminationofthesafetyvalve dischargepipingmustbeinanareawhereitisnotlikelytobecomepluggedbydebrisorsubjectedtofreezing. DANGER • PIPESAFETYVALVEDISCHARGETOASAFELOCATION. • DONOTINSTALLAVALVEINTHESAFETYVALVEDISCHARGELINE. • DONOTMOVESAFETYVALVEFROMFACTORYLOCATION. • DONOTPLUGSAFETYVALVEDISCHARGE. • DONOTINSTALLASAFETYVALVEWITHASETTINGGREATERTHAN15PSI. 4) Installdrainvalveintotappingonboilerleftsideusingthe2x3/4bushingprovided(seeFigure1). 5) Connectsystemsupplyandreturntoboiler.SeeFigure7.FORCESTM03throughFORCESTM06maybepipedwith oneortworisers.Install2”pluginTappingGifoptionalsecondsupplyAisnotused.Twosupplyrisersarerequiredon theFORCESTM07andFORCESTM08. 6) PipingwithaChiller-Iftheboilerisusedinconjunctionwithachiller,pipetheboilerinparallelwithchiller.Use isolationvalvestopreventchilledwaterfromenteringtheboiler. 106324-04 - 4/18...
  • Page 13 VIII. System Piping (continued) MINIMUM PIPE SIZE FORCESTM03 / FORCESTM04 / FORCESTM07 / FORCESTM05 / FORCESTM08 FORCESTM06 1½ 1½ 1¼ ¼ ** Optional FIGURE 7: STEAM BOILER PIPING FOR GRAVITY RETURN FIGURE 8: COMMON NEAR-BOILER PIPING MISTAKES 106324-04 - 4/18...

  • Page 14: Indirect Water Heater Piping

    IX. Indirect Water Heater Piping AllFORCESTMseriesboilersareequippedwithtappingstopermittheconnectionofaLinkSL™IndirectWater Heater,orotherindirectwaterheater.Inthistypeofsystem,hotboilerwaterisdrawnfrombelowthewaterlineand passedthroughtheheatexchangerintheindirectwaterheater.Thissectiondescribesboiler-sidepipingonly.RefertoLink SL™Installation,OperatingandServiceInstructionsforadditionalinformation Thecomponentsinthissystemandtheir functionsareasfollows: 1) Circulator-MountthecirculatorasshowninFigure9.Thecirculatorshouldbelocatedaslowandasclosetothe boileraspractical.Donotinstallvalves,orotherdeviceshavingasignificantpressuredrop,betweentheboiler andthecirculatorinlet.Allpipingbetweentheboilerandthecirculatorinletshouldbe1”,regardlessofthesizeof thepipingrequiredintherestofthesystem.SeeFigure10inPartXforwiringinformation. 2) “Y”Strainer-Installa“Y”strainertopreventsedimentfromaccumulatinginsidetheindirectwaterheater. 3) CheckValve-Preventsgravitycirculationthroughtheindirectwaterheaterwhentheboilerisrespondingtoacall forheat. 4) BoilerLimitControl-UseaSPSTbreak-on-risetemperaturelimitcontrolsuchastheHoneywellL4006A.Donot setthelimitabove180°Fasdoingsomaycausetheboilertosteamwhenthereisnocallforheat.SeeFigure10 forwiringinformation. 5) ValvesandUnions-Installshut-offvalves,drainvalves,andunionsinlocationsthatwillfacilitatemaintenanceof thesystem.Donotinstallanyvalvesbetweentheboilerandcirculatorinlet. IMPORTANT • Someindirectwaterheatersmaynotbesuitableforusewithasteamboiler.Consultthewaterheater manufacturer’sguidelinesbeforeinstallingitinthistypeofsystem. • Boilerwatertemperaturesandflowratesinthistypeofsystemmaybeconsiderablylowerthanthoseupon whichthewaterheatermanufacturer’sratingsarebased.Thismayresultinsubstantiallylongerwaterheater recoverytimes. FIGURE 9: INDIRECT WATER HEATER BOILER-SIDE PIPING 106324-04 - 4/18...

  • Page 15: Electrical

    X. Electrical WARNING Allwiringandgroundingmustbedoneinaccordancewiththeauthorityhavingjurisdictionor,intheabsenceofsuch requirements,withtheNationalElectricalCode(ANSI/NFPA70) 1) 120VoltWiring-Theboilershouldbeprovidedwithitsown15Abranchcircuitwithfuseddisconnect.All120volt connectionsaremadeinsidethejunctionboxontheleftsideoftheboiler.Removethetransformertogainaccesstothis box(alsoseeFigures11and12): • Hot(“black”)-Wirenuttoblacktransformerlead • Neutral(“white”)-Wirenuttowhitetransformerlead • Ground(“green”orbare)-Groundscrewinsidejunctionbox. 2)ThermostatWiring-Followthermostatmanufacturerinstructions.Toinsureproperthermostatoperation,avoid installationinareasofpooraircirculation,hotspots(nearanyheatsourceorindirectsunlight),coldspots(outside walls,wallsadjacenttounheatedareas,locationssubjecttodrafts).ProvideClassIIcircuitbetweenthermostatand boiler.Connectthermostatwireleadstothebluetransformerleadandbrownrelayleadinsidethejunctionbox.Setthe heatanticipatorto0.2A. 106324-04 - 4/18...
  • Page 16 X. Electrical (continued) Indirect Water Heater Wiring Figure10showsfieldwiringforanindirectwaterheater.AHoneywellR845AorequivalentDPSTrelayandtransformer isrequired.ThehighlimitdescribedinPartIXmustalsobesuppliedbytheinstaller.Acallforheatfromtheindirectwater heaterthermostatwillenergizetherelaymakingbothsetsofcontacts.Onesetofthesecontactsthenenergizesthecirculator. Theothersetofcontactswillmakethe“T”and“T”contactsontheburnerprimarycontrol,firingtheburner.Iftheboiler watertemperatureexceedsthehighlimitsettingof180°F,thehighlimitwillopenthe“T”-“T”circuitandtheburnerwill shutdown. Ifthereisacallforspaceheat,theheatingthermostatwillmakethe“T”-“T”circuitandtheboilerwillfirewithoutregard tothestatusoftheindirectwaterheater.Thelowwatercut-offandpressurelimitcontrolwillinterrupt120voltpowertothe burnerintheeventofalowwaterorexcessivepressurecondition. FIGURE 10: WIRING INDIRECT WATER HEATER TO BOILER 106324-04 - 4/18...
  • Page 17 X. Electrical (continued) FORCESTM Control System – Sequence of Operation (RefertoFigures11&12forladderandconnectiondiagrams) Sequence of Operation, Intermittent Ignition 1)Whentheboilerisenergized,24voltsisimmediatelyappliedtoterminals“1”(blue)and“4”(yellow)onthevent damper.Assumingthatthereisnocallforheat,andthatthedamperswitchisinthe“automatic”position,thedamper willclose.OnboilersequippedwithHydrolevelCG400Aprobetypelowwatercut-offs,voltageisalsoalwaysapplied toterminals“1”(blue)and“2”(yellow)onthelowwatercut-offtopowerthewaterlevelsensingcircuit. 2) Assumingthatwaterisabovethecut-offlevel,powerwillappearatterminal“3”ontheCG400ALWCO. 3)Assumingthatsteampressureisbelowthepressurelimitsetting,powerwillappearononesideofrelaycontact1R1 (Graylead).Relay1RistheR8225mountedunderthejunctionbox. 4) Acallforheatfromthethermostatenergizesrelaycoil1Rcausingcontacts1R1tomake.Currentthenflowsthrough contacts1R1topinterminal“2”(orange)attheventdamperandthedamperopens. 5) Oncetheventdamperisfullyopen,anendswitchinsidethedamperwillmake,energizingpin“3”(red)atthedamper. 6) Currentpassesfromterminal“3”ontheventdamperthoughtheflamerolloutandblockedvent(“spill”)switches.Under normalconditions,bothoftheseswitchesaremadeandvoltagewillthereforeimmediatelyappearacrossterminals “24V”and“24V(GND)”ontheignitionmodule. 7) Uponapplicationofvoltageacrossthe“24V”and“24V(GND)”terminals,theignitionmodulewillstartanignition sparkatthepilotandapply24voltsacrossthepilotvalve(terminals“PV”and“MV/PV”).
  • Page 18 X. Electrical (continued) FIGURE 11: WIRING DIAGRAM, HYDROLEVEL CG400A LOW WATER CUTOFF 106324-04 - 4/18...
  • Page 19 106324-04 - 4/18...

  • Page 20: System Start-Up

    XI. System Start-up Usethefollowingprocedureforinitialstart-upoftheboiler: 1) Makesurethattheboilerisfilledwithwatertothenormalwaterline(283/4inchesabovethefloororpadonwhichthe boilerisinstalled) 2) Checkallnewgaspipingforleaksandpurgepipingsectionsthatarefilledwithair.SeePart4oftheNational Fuel Gas Codeforadditionalinformationontestingandpurginggaslines. WARNING • NEVERUSEAFLAMETOCHECKFORGASLEAKS. • MAKESURETHATTHEAREAAROUNDTHEBOILERISCLEARANDFREEFROM COMBUSTIBLEMATERIALS,GASOLINE,ANDOTHERFLAMMABLEVAPORSANDLIQUIDS. • DAMPERMUSTBEINOPENPOSITIONWHENAPPLIANCEMAINBURNERISOPERATING. 3) Verifythatventsystemiscompleteandfreeofobstructionsbeforeattemptingtofireboiler. 4) Inspectallwiringforlooseoruninsulatedconnections. 5) Makesurethemainburnersareseatedproperlyintherearofburnertrayandonorifices. 6) Adjuststeampressurelimitcontrolforacut-inpressureof0.5psiandadifferentialpressureof1psi. 7) Adjustthermostattothehighestsetting. 8) StarttheboilerusingtheOperatingInstructions.SeeFigure14. 9) Uponinitialstart-up,thegastrainwillbefilledwithair.Evenifthegaslinehasbeencompletelypurgedofair,it maytakeseveraltriesforignitionbeforeaflameisestablished.Onceaflamehasbeenestablishedforthefirsttime, subsequentcallsforburneroperationshouldresultinaflameonthefirsttry. 10) Observepilotburnerflame.Pilotburnerproducesthreeflames.Thecenteroneshouldbeasteadymediumblueflame coveringaround3/8”to½”ofsparkelectrode/flamerod.SeeFigure13. 12) Makesureventdamperisinopenpositionwhenmainburnersarefiring.
  • Page 21 XI. System Start-up (continued) WARNING FAILURE TO FOLLOW THE FOLLOWING PROCEDURE EXACTLY COULD RESULT IN OVER- FIRING OF THE BOILER AND A CARBON MONOXIDE HAZARD. 16) Checkthemanifoldpressureandadjustifnecessary.Todothis,usethefollowingprocedure: a) Connectamanometertotheinletpressuretaponthegasvalve(seeFigure16). b) Checktheinletpressurewithallgasappliancesonandoff.Theinletpressureattheboilermustbewithinthe followinglimitsregardlessofwhatcombinationofappliancesisfiring: InletPress(inchesw.c.) NaturalGas LPGas* Min. 5.0 11.0 Max. 14.0 13.0 Iftheinletpressurefallsoutsideoftheselimits,findandcorrectthecauseoftheproblembeforeproceeding further.
  • Page 22 XI. System Start-up (continued) FIGURE 14: OPERATING INSTRUCTIONS 106324-04 - 4/18...
  • Page 23 XI. System Start-up (continued) FIGURE 15: MAIN BURNER FLAME - 1” BURNERS 17) Testthermostatoperationwhiletheboilerisrunning.Turnthethermostattothelowestsetting.Bothpilotburnerand mainburnersshouldstopfiring.Raisethethermostatbacktothehighestsetting.Thepilotburnerandmainburners shouldrelight. 18) Verifylowwatercutoffoperationwhiletheboilerisrunning.Slowlyopendrainvalveanddrainboileruntilthewater leveldropsbelowlowwatercutoffline.Waterstillshouldbevisibleinthegaugeglasswhenthelowwatercutoffshuts downthemainburners.Bothpilotburnerandmainburnersshouldstopfiring.Makesurepressurelimit,thermostator othercontrolshavenotshutofftheboiler.Upontestcompletionrefilltheboilertothenormalwaterlevel. 19) Checkpressurelimitcontroloperation.Whensteampressureisregisteredonpressuregauge,lowerpressurelimitsetting belowgaugereading.Bothpilotburnerandmainburnersshouldstopfiring.Raisepressurelimitsettingabovegauge reading.Thepilotburnerandmainburnersshouldrelight. 20) Aftertheboilerhasoperatedforapproximately30minutes,checktheboilerandheatingsystempipingforleaks.Repair anyleaksfoundatonce. 21) Inspecttheventsystemforfluegasleaks.Repairanyleaksfoundbeforeleavingtheboilerinoperation. 22) Replacementofasteamboilertendstobreaklooseaccumulatedscalefromthesystem. 23) Afternewboilerhasbeeninstalledandputintocontinuousoperationforseveraldays,cleantheboilerofoil,grease, sludge,andothercontaminantsthatmayhavebeenpresentinexistingpiping.Thiswillpreventunsteadywaterlineand watercarryoverintosupplymain.Theboilerboil-outshouldbedoneasfollows: a) TurnoffgassupplytoboilerpertheOperatingInstructions.SeeFigure14. b) Drainwaterfromboileruntilaboutoneinchofwaterisvisibleingaugeglass. c) Runahoseortemporarypipingfromtheboilerdrainvalvetoalocationwherehotwatercanbesafelydischarged.
  • Page 24 XI. System Start-up (continued) e) TurnoffgassupplytoboilerpertheOperatingInstructions-seeFigure14.Drainhotwaterfromboilerthrough boilerdrainvalvetoalocationwherehotwatercanbesafelydischarged.Refilltheboilertonormalwaterlinelevel. Ifwaterinthegaugeglassdoesnotlookclear,repeataboveboil-outprocedureagainuntilwaterisclears. f) Reinstallsafetyvalveandrelatedpiping. g) ConductpHandAlkalinitytestofwaterinthesystem.ThepHreadingshouldbein7to11range. NOTE Whensubstantialamountofmake-upwaterisusedduetolostcondensate,orwhenmake-upwaterishardorcorrosive, watertreatmentisrequired.Contactqualifiedwatertreatmentcompanyforrecommendedwatertreatmentcompounds andprocedures. FIGURE 16: GAS VALVE DETAIL - HONEYWELL VR8204 AND VR8304 106324-04 - 4/18...

  • Page 25: Service Instructions

    XII. Service Instructions On a continuous basis: 1) Keeptheareaaroundtheboilerfreeandclearfromcombustiblematerials,gasoline,andotherflammablevaporsand liquids. 2) Keeptheareaaroundtheboilerandboilerroomventilationopeningsclearofobjectswhichmightobstructtheflowof combustionandventilationair. Every three months: Boilerwatermustbemonitoredthroughouttheheatingseason.Boilerwatermustbetestedeverythree(3)monthsfor theconstituentsshowninTable3.Ifchloride,totalhardness,orpHlevelsintheboilerwaterareoutsideofthelevelsshown inTable3,excessivemake-upwaterisbeingadded.Findandrepairallsystemleaks,drain,andrefilltheboilerwithfresh make-upwaterthatmeetsthecriteriainTable3.Thenbringtheboilertopressurefor15minutestodriveoffexcessoxygen. TABLE 3: STEAM BOILER WATER QUALITY CRITERIA (Concentration Limits for Make-up Water & Boiler Water) Constituent Make-up Water Boiler Water Chlorides ≤...
  • Page 26 XII. Service Instructions (continued) CAUTION LABELALLWIRESPRIORTODISCONNECTIONWHENSERVICINGCONTROLS.WIRINGERRORS CANCAUSEIMPROPERANDDANGEROUSOPERATION.VERIFYPROPEROPERATIONAFTER SERVICING. 11) Inspecttheboilerandsystemforleaks. 12) InspecttheHydroLevelCG400Alowwatercut-off: Removeandinspecttheprobeforscaleandsedimentbuildup.Cleananysedimentorscalefromtheprobewitha scouringpadorsteelwool.ConsulttheHydrolevelCG400Amanualforanyadditionalmaintenanceinformation.Test thelowwatercut-offbeforeplacingtheboilerbackintoservice. 13) Allowtheboilertocooltoroomtemperature.Removethedrainvalveand2x3/4bushingontheleftsideoftheboiler. Useaflashlighttoinspectthebottomrowofpushnipplesforaccumulatedscaleormud.Ifasignificantamountis present,usethefollowingproceduretocleantheinsideoftheheatexchanger: a) Temporarilyinstalla11/4inchorlargerfullportballvalveinplaceoftheboilerdrain.Temporarilypipetheoutlet ofthisvalvetoalocationwherehotwaterandsteamcanbesafelydischarged. b) Makesurethatthisvalveisclosedandthatthewaterlevelisatthenormalwaterline. c) Ifakingvalveispresentinthesteammaintakeoff,closeit.Alternatively,temporarilyreplaceenoughofthe ventsonthemainsand/orradiatorswithplugssothat2-5psicanbedevelopedwhentheboilerisfired. d) Firetheboilerandallowittosteamuntil2-5psiisregisteredonthegauge. e) Turnofftheburnersandimmediatelyfullyopenthe1-1/4valve. f) Allowtheboilertoblowdownuntileitherthewaterrunsclearorthewaterlevelreachesthebottomofthegauge glass. g) Allowallpartsoftheboilertocooltoroomtemperature.Draintheboilercompletelyandremovethe1-1/4valve. h) Ifsignificantmudorscaleisstillpresentinthebottomoftheboiler,repeatsteps(b)through(g)untilallmudor scaleisremoved. i) Onceallmudorscaleisremoved,replacethe1-1/4valveandtemporaryblow-downpipingwiththestandarddrain valve.Afterallpartsoftheboilerareatroomtemperature,refilltheboilertothenormalwaterline.
  • Page 27 XII. Service Instructions (continued) CAUTION If,duringnormaloperation,itisnecessarytoaddwatertothisboilermorefrequentlythanonceamonth,consultaqualified servicetechniciantocheckyoursystemforleaks.Aleakysystemwillincreasethevolumeofmake-upwatersuppliedtothe boilerwhichcansignificantlyshortenthelifeoftheboiler.Entrainedinmake-upwateraredissolvedmineralsandoxygen. Whenthefresh,coolmake-upwaterisheatedintheboilerthemineralsfalloutassedimentandtheoxygenescapesasagas. Bothcanresultinreducedboilerlife.Theaccumulationofsedimentcaneventuallyisolatethewaterfromcontactingthecast iron.Whenthishappensthecastironinthatareagetsextremelyhotandmayeventuallycrack.Thepresenceoffreeoxygen intheboilercreatesacorrosiveatmospherewhich,iftheconcentrationbecomeshighenough,cancorrodethecastironthrough fromtheinside.Sinceneitherofthesefailurestypesarearesultofacastingdefectthewarrantydoesnotapply. Heat Exchanger Cleaning Procedure 1) Turnoffelectricalpowerandgassupplytotheboiler 2) Disconnectthedamperandventconnectorfromtheboiler. 3)Removetheupperfrontandtopjacketpanels.Ifpossible,removetherearandleftsidejacketpanels 4) Removetheburners. 5) Removetheblockedvent(“spill”)switch 6) Removethe¼-20nutsandwashersholdingthefluecollectorontotheheatexchanger. 7) Carefullyremovethefluecollectorgasketstripsandsetthemaside. 8) Removethefluecollectorfromtheheatexchanger. 9) Cleanthefluepassagewaysusingastiffbristlebrush.Becertainthatallforeignmaterialisremovedfromthegaps between the pins 10) Cleanthebottomsurfacesoftheheatexchanger 11) Putalightinthecombustionchamberandlookthroughthefluepassagesfromthetoptoverifythattheyhavebeen thoroughlycleaned.
  • Page 28 XII. Service Instructions (continued) WARNING SOOTDEPOSITSINTHEFLUEPASSAGESAREASIGNTHATTHEBOILERMAYBEOPERATING ATHIGHCARBONMONOXIDE(CO)LEVELS.AFTERCLEANINGTHEBOILEROFSOOTDEPOSITS, CHECKTHECOLEVELINTHEFLUEGASTOINSURETHATTHEBOILERISOPERATINGPROPERLY. IfitisnecessarytocheckCO,useacombustionanalyzer,orotherinstrumentwhichisdesignedtomeasureCOinflue gas.ACO“sniffer”designedfortestingCOlevelsinambientaircannotbeusedtocheckboilercombustion.Takeaflue gassamplebyinsertingasampleprobethroughthedraftdiverteropeningandintothefluecollectorsothatthesampleis takenintheareadirectlyovertheheatexchanger.Donottakeasampleuntiltheboilerhasbeenfiringforatleastfivemin- utes. AnormalCOreadingforaFORCESTMseriesboilerislessthan50ppm(0.005%).Areadingofmorethan100ppm (0.01%)isindicativeofacombustionproblem. SomecausesofexcessiveCOinclude: • Incorrectlysizedmainburnerorificeforthealtitudeatwhichboilerisinstalled • Crookedorout-of-roundorificeholes(neverattempttodrillorificeforthisboilerinthefield) • Partiallypluggedfluepassages • Impropermanifoldpressure • Foreignmaterialinburnerventurisorburnerports • Leakinsealbetweenfluecollectorandheatexchanger • Inadequatesupplyofcombustionair 106324-04 - 4/18...

  • Page 29: Troubleshooting

    XIII. Troubleshooting Thefollowingpagescontaintroubleshootingchartsforuseindiagnosingcontrolproblems.Tousethesecharts,gotothe boxmarked“Start”atthetopofthechartonpage30or32andfollowtheappropriatepaththoughthechartuntilaboxwith alistofpossiblecausesisreached.Iftheproblemisknowntobewithintheignitionsystem,godirectlytotheignitionsystem troubleshootingguidefortheboileronpage32.Inusingthesecharts,thefollowingshouldbekeptinmind: 1) Thesechartsareonlymeanttobeusedbyaprofessionalheatingtechnicianasanaidindiagnosingcontrolproblems. 2) Whereapplicable,followallprecautionsoutlinedintheOperatingInstructions.SeeFigure14. 3) Ingeneral,thesechartsassumethattherearenolooseormiswiredelectricalconnections.Beforeusingthesecharts, inspectallelectricalconnectionsontheboilertomakesurethattheyaretight.Also,checkthewiringontheboiler againsttheappropriatewiringdiagraminFigures11and12. 4) Thepossiblecausesattheendofeachbranchinthesechartsarenotlistedinorderoflikelihood.Allcontrolsonthe FORCESTMaretestedatleastonceinthemanufacturingprocessandadefectivecontrolorcomponentisgenerallythe leastlikelycause.Beforereplacingacomponent,trytoruleoutallotherpossiblecauses. 5) Thesetroubleshootingchartsassumethattheventdamperisclosedatthebeginningofthetroubleshootingprocess.With the120voltsappliedtotheboilerandnocallforheat,thedampershouldgototheclosedposition.Ifitdoesnot,dothe following: • Confirmthat120voltsisappliedtotheboilerandthatthereisnocallforheat. • Makesurethattheswitchonthedamperisinthe“automatic”position. • Unplugtheharnessfromthedamperandcheckfor24voltsacrosspin#1(blue)andpin#4(yellow). • Ifvoltageispresent,thedamperisdefectiveorthereisanobstructioninthepathofthedamperblade. • Ifnovoltageispresent,thereiseitheralooseconnectioninthedamperharnessorthetransformerisdefective. 6) Ifthechartsindicatethatthetransformerisdefective,itispossiblethatthistransformerhasbeendestroyedbyashort circuitintheboilerwiring.Beforereplacingthetransformer,carefullyinspectalllowvoltagewiringontheboilerfor placeswhereitistouchingtheframeoftheboilerorwiringontheothersideofthetransformer. 7) IfthechartsindicatethattheR8225relayisdefective,thereisagoodchancethatasecondtransformerispresentinthe thermostatcircuit,resultingintheapplicationof48voltsacrosstherelaycoil.Inolderbuildings,thistransformermaybe hiddeninalocationfarfromtheboiler.Ifthissecondtransformerexists,itmustbefoundandremovedbeforetheR8225 isreplaced.
  • Page 30 XIII. Troubleshooting (continued) Troubleshooting Chart for FORCESTM Boilers Equipped with Hydrolevel CG400A Low Water Cut-offs and Vent Dampers Caution: Read page 29 before attempting to use this chart 106324-04 - 4/18...
  • Page 31 XIII. Troubleshooting (continued) 106324-04 - 4/18...
  • Page 32 XIII. Troubleshooting (continued) Ignition System Troubleshooting Chart Caution: Read page 29 before attempting to use this chart 106324-04 - 4/18...

  • Page 33: Repair Parts

    XIV. Repair Parts All FORCESTM™ Repair Parts may be obtained by contacting your local Ferguson branch. 106324-04 - 4/18...
  • Page 34 XIV. Repair Parts (continued) Quantity Description Part No. FORCESTM03 FORCESTM04 FORCESTM05 FORCESTM06 FORCESTM07 FORCESTM08 617100321 617100421 617100521 Heat Exchanger Assembly (Complete) 617100621 617100721 617100821 718600391 718600491 718600591 Base Tray 718600691 718600791 718600891 718600311 718600411 718600511 Base Wrapper 718600611 718600711 718600811 718600305 718600405 718600505...
  • Page 35 XIV. Repair Parts (continued) 106324-04 - 4/18...
  • Page 36 XIV. Repair Parts (continued) Quantity Description Part No. FORCESTM03 FORCESTM04 FORCESTM05 FORCESTM06 FORCESTM07 FORCESTM08 Base End Insulation 720601 72060035 72060045 72060055 Base Rear Insulation 72060065 72060075 72060085 Base Leg Assembly 6186001 Screw, Self Tapping, Phillips Pan Head, 1/4 80860700 -20 x 1/2" 1/2”...
  • Page 37 XIV. Repair Parts (continued) 106324-04 - 4/18...
  • Page 38 XIV. Repair Parts (continued) Quantity Description Part No. FORCESTM03 FORCESTM04 FORCESTM05 FORCESTM06 FORCESTM07 FORCESTM08 Main Burner with Pilot Bracket 8236118 Main Burner Less Pilot Bracket 8236119 104810-03 104810-04 104810-05 Manifold 104810-06 104810-07 104810-08 Nat. Gas Main Burner Orifice, #44 822712 Orange Nat.
  • Page 39 XIV. Repair Parts (continued) 106324-04 - 4/18...
  • Page 40 XIV. Repair Parts (continued) Quantity Part Description Number FORCESTM03 FORCESTM04 FORCESTM05 FORCESTM06 FORCESTM07 FORCESTM08 Damper Wire Harness 105083-01 Blocked Vent Switch 104965-01 Harness J-Box FRS Harness 105084-01 CG400A L.W.C.O - J-Box 105085-01 Harness Pressure Limit - J-Box 105086-01 Harness Intermittent Ignition 104832-01 Harness 106442-03...
  • Page 41 106324-04 - 4/18...

  • Page 42: Appendix A - Tapping Locations

    Appendix A - Tapping Locations FIGURE A1: TAPPING LOCATIONS (SEE TEXT FOR TAPPING USES) TABLE A1: TRIM AND CONTROL INSTALLATION IN SECTION TAPPINGS Size Tapping Steam Boiler with Probe LWCO (NPT) Supply Bush to ¼ ½ Pressure Gauge ½ Gauge Glass Return ¾...
  • Page 43 106324-04 - 4/18...
  • Page 44 106324-04 - 4/18...

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