PROSELECT FORCE02, FORCE03, FORCE04, FORCE05, FORCE06 Installation Manual
...
INSTALLATION, OPERATING
AND
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
FORCE
Heating Contractor Phone Number
Address
105941-01 - 11/14
Boiler Serial Number Installation Date
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 approved the Force™ Series Boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval
Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas tter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various
risk levels, or to important information concerning product life.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Table of Contents
I. Pre-Installation .................................... 5
II. Unpack Boiler .....................................6
III. Water Piping and Trim ........................7
IV. Gas Piping .........................................10
V. Venting ..............................................11
VI. Electrical ............................................13
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
NOTICE
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
VII. System Start-up and Checkout ..........16
VIII. Operation ..........................................19
IX. Service and Maintenance ...................21
X. Troubleshooting ................................24
XI. Repair Parts .......................................26
Table 1A: Ratings
Force Gas Ratings
Boiler Model Input (MBH) DOE Heating Capacity (MBH) Net AHRI Rating Water (MBH)
FORCE02 37.5 30 26 82
FORCE03 62 50 43 82
FORCE04 96 78 68 82
FORCE05 130 106 92 82
FORCE06 164 134 117 82
FORCE07 198 164 143 82
FORCE08 232 191 166 82
FORCE09 266 218 190 82
FORCE10 299 244 212 82
(1)
Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1.15. Consult manufacturer before selecting
boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping
systems, etc.
2
(1)
AFUE (%)
Table 1B: Dimensions and Connections
Boiler Model
FORCE02 1¼ 1¼ 4 ½ ¾ ¾
FORCE03 1¼ 1¼ 4 ½ ¾ ¾
FORCE04 1¼ 1¼ 5 ½ ¾ ¾
FORCE05 1¼ 1¼ 6 ½ ¾ ¾
FORCE06 1¼ 1¼ 6 ½ ¾ ¾
FORCE07 1¼ 1¼ 7 ¾ ¾ ¾
FORCE08 1¼ 1¼ 7 ¾ ¾ ¾
FORCE09 1¼ 1¼ 8 ¾ ¾ ¾
FORCE10 1¼ 1¼ 8 ¾ ¾ ¾
Supply NPT
(inch)
Electrical Requirements: 120VAC, 60 Hz, 1-ph, less than 12A
Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valve.
Return NPT
(inch)
Vent (inch) Gas NPT (inch)
Relief Valve
NPT (inch)
NPT (inch)
Table 1C: Weights and Volume
Drain
Boiler Model
FORCE02 220 2.4
FORCE03 270 3.2
FORCE04 320 4.0
FORCE05 370 4.7
FORCE06 420 5.5
FORCE07 470 6.3
FORCE08 520 7.0
FORCE09 570 7.8
FORCE10 620 8.6
Shipping Weight
(lbs)
Water Content
(gal)
3
Figure 1: Minimum Clearance to Combustible Materials
4
I. Pre-Installation
WARNING
Carefully read all instructions before installing
boiler. Failure to follow all instructions in proper
order can cause personal injury or death.
A. Inspect shipment carefully for any signs of damage.
All equipment is carefully manufactured, inspected
and packed. Our responsibility ceases upon delivery
of boiler to carrier in good condition. Any claim
for damage or shortage in shipment must be led
immediately against carrier by consignee. No claims
for variances or shortages will be allowed by Boiler
Manufacturer, unless presented within sixty (60) days
after receipt of equipment.
B. Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to National
Fuel Gas Code, ANSI Z223.1/NFPA 54. Where
required by the authority having jurisdiction, the
installation must conform to the Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1.
C. Appliance is design certied for installation on
combustible ooring. The boiler must not be installed
on carpeting.
D. Provide clearance between boiler jacket and
combustible material in accordance with local re
ordinance. Refer to Figure 1 for minimum clearance
from combustible material for alcove installation.
Provide 1/2" clearance from water piping to
combustible materials.
E. Provide practical service clearances. A minimum
of 24" from the right side and front jacket panels is
recommended for servicing but may be reduced to
minimums shown in Figure 1.
F. Install on level oor. For basement installation provide
concrete base if oor is not level or if water may be
encountered on oor around boiler.
G. Protect gas ignition system components from
water (dripping, spraying, rain, etc.) during boiler
operation and service (circulator replacement, control
replacement, etc.).
H. Provide combustion and ventilation air in accordance
with the section "Air for Combustion and Ventilation,"
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
or applicable provisions of local building codes.
WARNING
Adequate combustion and ventilation air must be
provided to assure proper combustion.
The following guideline is based on the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
Volume [ft³] = Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconned
space.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a conned space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1 perm or less with openings gasketed
and sealed, and;
b. Weather-stripping has been added on openable
windows and doors, and;
c. Caulking or sealants applied in joints around
window and door frames, between sole
plates and oors, between wall-ceiling joints,
between wall panels, at plumbing and electrical
penetrations, and at other openings.
5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air inltration through cracks
around windows and doors.
6. For boiler located within unconned space in
building of unusually tight construction or within
conned space, provide outdoor air through two
permanent openings which communicate directly or
by duct with the outdoors or spaces (crawl or attic)
freely communicating with the outdoors. Locate one
opening within 12 inches of top of space. Locate
remaining opening within 12 inches of bottom of
space. Minimum dimension of air opening is 3
inches. Size each opening per following:
5
I. Pre-Installation (continued)
a. Direct communication with outdoors. Minimum
free area of 1 square inch per 4,000 Btu per hour
input of all equipment in space.
b. Vertical ducts. Minimum free area of 1 square
inch per 4,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
c. Horizontal ducts. Minimum free area of 1
square inch per 2,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
Alternate method for boiler located within conned
space. Use indoor air if two permanent openings
communicate directly with additional space(s) of
sufcient volume such that combined volume of all
spaces meet criteria for unconned space. Size each
opening for minimum free area of 1 square inch per
1,000 Btu per hour input of all equipment in spaces,
but not less than 100 square inches.
7. Ventilation Duct Louvers and Grilles. Equip outside
openings with louvers to prevent entrance of rain
and snow, and screens to prevent entrance of insects
and rodents. Louvers and grilles must be xed in
open position or interlocked with equipment to open
automatically before burner operation. Screens must
not be smaller than ¼ inch mesh.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
I. Do not install boiler where gasoline or other
ammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays,
paint removers, fabric softeners, etc.) are used or stored.
II. Unpack Boiler
CAUTION
Do not drop boiler. Do not bump boiler jacket
against oor.
A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift outside container and remove with all other
inside protective spacers and bracing. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
6
D. Remove all boiler hold-down fasteners.
E. Tilt the boiler to one side and slide a wooden slat under
the two raised feet.
F. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
G. Slide the boiler forward or backward off the skid using
the two wooden slats as runners.
H. Move boiler to its permanent location.
III. Water Piping and Trim
WARNING
appropriate valves to prevent chilled medium from
entering boiler. See Figure 3.
Failure to properly pipe boiler may result in
improper operation and damage to boiler or
building.
A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water.
Oxygen contamination sources are system leaks
requiring addition of makeup water, ttings, and
oxygen permeable materials in distribution system.
Eliminate oxygen contamination by repairing system
leaks, repairing ttings, and using non-permeable
materials in distribution system.
B. Install circulator with anges, gaskets and bolts
provided.
C. Install Safety Relief Valve. See Figure 2. Safety Relief
Valve must be installed with spindle in vertical position.
WARNING
Safety relief valve discharge piping must be
piped near oor to eliminate potential of severe
burns. Do not pipe in any area where freezing
could occur. Do not install any shut-off valves.
D. Connect system supply and return piping to boiler.
Refer to Figures 2, 3, 4, & 5. Maintain minimum ½
inch clearance from hot water piping to combustible
materials.
E. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled medium
piped in parallel with the heating boiler using
F. If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
ow control valves or other automatic means to prevent
gravity circulation of boiler water during operation of
cooling system.
G. Use a boiler bypass if the boiler is to be operated
in a system which has a large volume or excessive
radiation where low boiler water temperatures may be
encountered (i.e. converted gravity circulation system,
etc.).
Remove circulator and install pipe tee between
circulator and boiler return along with second tee in
supply piping as shown in Figures 4 and 5. Bypass
should be same size as the supply and return lines with
valves located in bypass and supply outlet as illustrated
in Figures 4 and 5 in order to regulate water ow to
maintain higher boiler water temperatures.
Set by-pass and boiler supply valves to half throttle
position to start. Operate boiler until system water
temperature reaches normal operating range.
Adjust valves to provide 180° to 200°F supply water
temperature. Opening the boiler supply valve will raise
system temperature, while opening by-pass valve will
lower system supply temperature.
H. If it is required to perform a long term pressure
test of the hydronic system, the boiler should rst be
isolated to avoid a pressure loss due to the escape of air
trapped in the boiler.
To perform a long term pressure test including the
boiler, ALL trapped air must rst be removed from the
boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler contained
trapped air.
Figure 2: Near Boiler Piping
Figure 3: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
7
III. Water Piping and Trim (continued)
8
Figure 4: Recommended Water Piping for Zone Valve Zoned Heating Systems
III. Water Piping and Trim (continued)
Figure 5: Recommended Water Piping for Circulator Zoned Heating Systems
9
IV. 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. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum gas valve inlet pressure is listed on rating
label.
2. Maximum gas demand. Consider existing and
expected future gas utilization equipment (i.e. water
heater, cooking equipment).
B. Connect boiler gas valve to gas supply system.
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liqueed petroleum gas.
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve.
See Figure 6.
4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, ANSI/NFPA 70.
C. Pressure test. The boiler and its gas connection must
be leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over
½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at ½ psig or less, isolate boiler from gas supply
piping by closing boiler's individual manual shutoff
valve.
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonammable
solution. Do not use matches, candles, open ames,
or other ignition source.
10
Figure 6: Pilot and Gas Piping
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