PROSELECT FORCEOL084, FORCEOL115, FORCEOL147, FORCEOL189 Installation Manual

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Page 1

INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

FORCEOL™ SERIES

CAST IRON OIL-FIRED BOILER

9700609

As an ENERGY STAR

U.S. Boiler Company, Inc. has determined that the FORCE OIL Series boilers meets the ENERGY

guidelines for energy

STAR

efciency established by the United

States Environmental Protection Agency (EPA).

Partner,

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 Part Number FORCEOIL _ _ _

Heating Contractor Phone Number

Address

106346-02 - 8/15

Boiler Serial Number Installation Date

Price - $5.00

Page 2

IMPORTANT INFORMATION - READ CAREFULLY

All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to the following Standards:

USA BOILERS A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for recommended installation practices. B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Venting requirements. C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety devices. D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations.

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.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

This boiler has a limited warranty. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in accordance with these instructions.

Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.

Page 3

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the appliance before installing, starting-up, operating, maintaining or servicing this appliance. Keep this manual and literature in legible condition and posted near appliance for reference by owner and service technician.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency.

All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler.

Installation is NOT complete unless a pressure relief valve is installed into the 3/4" tapping located on return piping that was installed into boss on top of rear section - See "Packaged Boiler Assy - Trim & Controls" and "Water Boiler Piping" Sections of this manual for details.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete including verifying that the limit sensor is fully installed.

Failure to properly install Limit Sensor may result in property damage, personal injury or loss of life due to elevated operating temperatures and/or pressures.

This boiler is suitable for installation on combustible ooring. DO NOT install boiler on carpeting.

DO NOT tamper with or alter the boiler or controls.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has

accumulated.

When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged, or if there is evidence of previous damage, burner swing door insulation must be replaced immediately.

Oil Burner and Controls must be checked at least once a year or as may be necessitated.

DO NOT operate unit with jumpered or absent controls or safety devices.

DO NOT operate unit if any control, switch, component, or device has been subject to water.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.

Page 4

WARNING

This boiler contains very hot water under high pressure. DO NOT unscrew any pipe ttings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. DO NOT rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. DO NOT touch any components unless they are cool.

This boiler must be properly vented. The boiler must be connected to an approved chimney or vent system in good condition. Serious property damage could result if the boiler is connected to a dirty or

inadequate chimney or vent system. The chimney must be inspected for any obstructions and cleaned prior to each heating season. A clean and unobstructed chimney ue is necessary to produce the minimum draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. DO NOT

operate boiler with the absence of an approved vent system. Evidence of loose debris and or condensate

induced stains at the base of the chimney ue, connector or smokepipe joints may be signs of condensing ue gases. Flue gas condensate is corrosive, which requires special consideration and must be addressed

immediately. Refer to "Natural Draft Venting (Chimney)" listed in Table of Contents below .

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.

This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

This boiler is designed to burn No. 2 fuel oil only. DO NOT use gasoline, crankcase drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. DO NOT convert to any solid fuel (i.e. wood, coal). DO NOT convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper, wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and

free of re hazards.

All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe

property damage, personal injury or loss of life. Before opening swing door turn off service switch to

boiler to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing

door fasteners completely when service is completed.

TABLE OF CONTENTS

I. General Information 5 XI. Operating........................................................... 47

II. Pre-Installation ................................................ 7 XII. Maintenance & Service Instructions ................ 48

III. Packaged Boiler Assy. - Trim & Controls ......... 9 XIII. Boiler Cleaning ................................................ 50

IV. Water Boiler Piping .......................................... 17 XIV. Trouble Shooting ............................................. 53

V. Indirect Water Heater Piping ........................... 21 X V. Repair Parts .................................................... 55

VI. Natural Draft Venting (Chimney) ..................... 22

VII. Direct Venting / Air Intake Piping...................... 26

VIII. Electrical .......................................................... 33

IX. Oil Piping ......................................................... 38

X. System Start-Up............................................... 40

Appendix A

Burner Specications........................................

Appendix B

Low Water Cut Off............................................

Page 5

RELIEF

VALVE

SMOKEBOX

PRESURE

CLEAN

TAPPING

OUT COVER

DRAIN VALVE

"NPT SYSTEM

COLLAR

SMOKEBOX COLLAR

SPANNER BAR W/

ADJUSTABLE LEGS

Figure 1: FORCEOL084 through FORCEOL189

CONNECTION

"NPT SYSTEM RETURN

12" MIN

CLEARANCE

(SEE NOTE 1)

REAR SERVICE

5 "

BOILER

CONTROL

SUPPLY

CONNECTION

GAUGE

TEMP/PRESSURE

FRONT SERVICE

DIA.

CLEARANCE

(FLUEWAY CLEANING)

I: GENERAL INFORMATION

20 "

WELL

IMMERSION

PORT

DOOR

FLAME

BURNER

SWING

OBSERVATION

BURNER

BECKETT AFG

(SHOWN)

19" MIN.

(SEE NOTE 3)

(FULLY OPEN)

BURNER SWING

DOOR CLEARANCE

1. THIS DIMENSION INCREASES AND IS CONTROLLED BY SMOKEPIPE ARRANGEMENT.

2. DRAIN VALVE AND RELIEF VALVE/FITTINGS SHIPPED LOOSE.

3. BOILER SHIPPED WITH STANDARD RIGHT HAND HINGE CONFIGURATION, BUT CAN

BE CONVERTED TO LEFT HAND HINGE. APPLY CLEARANCE ACCORDINGLY.

NOTES:

Page 6

Weight (LB.)

Actual Shipping

Sq. Ft.

Heat Transfer

Surface Area -

Vent

Dia. Inch

Connector

Kit Part

Number

Height Ft.

Gallons

Water Content -

Dimensions See Figure 1

“A” “B” “C”

Burner Capacity AFUE % Minimum Chimney Requirements Direct Vent System

In. x In.

Rectangle

Dia.

Round In.

GPH MBH Water Boiler

i: General Information (continued)

FORCEOL084 17” 24” 5” 7.70 13.29 430

Boiler Model No.

TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1)

FORCEOL115 17” 24” 5” 7.70 13.29 430

FORCEOL147 23” 24” 6” 11.08 20.29 545

FORCEOL189 29” 30” 6” 14.46 27.29 658

NOTE: 1. Maximum Working Pressure: Water: 30 PSI Shipped From Factory (Standard),

50 PSI Optional

TABLE 1B: RATING DATA

Boiler Model No.

FORCEOL084 0.60 84 87 6 8 x 8 15 N/A N/A

FORCEOL115 0.80 115 87 6 8 x 8 15 N/A N/A

FORCEOL147 1.05 147 87 6 8 x 8 15 106401-01 5

FORCEOL189 1.35 189 87 7 8 X 8 15 106401-01 5

Page 7

II: PRE-INSTALLATION

A. INSPECT SHIPMENT carefully for any signs of

damage.

1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition.

2. Any claims for damage or shortage in shipment

must be led immediately against the carrier by the

consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after receipt of goods.

B. LOCATE BOILER in front of nal position before

removing crate. See Figure 1.

1. LOCATE so that vent pipe connection to chimney will be short and direct.

2. BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR. Boiler cannot be installed on carpeting.

3. FOR BASEMENT INSTALLATION, provide a

solid elevated base, such as concrete, if oor is not level, or if water may be encountered on oor around

boiler.

4. PROVIDE RECOMMENDED SERVICE CLEARANCE, if applicable, as follows:

a. Clearance from Jacket Front Panel -

• 24" for servicing burner

• 24" for ueway cleaning (FORCEOL084

through FORCEOL147).

• 30" for ueway cleaning (FORCEOL189)

b. Clearance from Jacket Left Side Panel -

• 19" for burner swing door, if opened fully with

burner mounted, otherwise 1" with burner removed

• 12" access clearance to service rear of boiler if right side clearance is less than 12"

• 3" minimum if right side clearance is 12" or larger to access and service rear of boiler.

c. Clearance from Jacket Right Side Panel -

• 3" minimum if left side clearance is 12" or larger to access and service rear of boiler.

d. Clearance from Jacket Rear Panel -

• 12" minimum for rear smokebox cleaning

(NOTE: This dimension will also be

controlled by horizontal to vertical to horizontal smokepipe arrangement - Chimney Vent (see Figures 2A and 13).

• 24" for rear smoke box cleaning and disconnecting vent pipe from boiler adaptor for servicing (if required) - Direct Vent (see Figures 2B and 25).

18"18"

6" 6"

24"

Figure 2A: Chimney Vent - Minimum Installation Clearances To Combustible Materials (Inches)

NOTES: 1. Listed clearances comply with American National Standard

ANSI/NFPA 31, Standard for the Installation of Oil Burning Equipment.

2. FORCEOL boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances

cannot be reduced for alcove or closet installations.

18"

3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31 standard.

18"

Page 8

II: Pre-Installation (continued)

5. For minimum clearances to combustible materials. See Figures 2A and 2B.

WARNING

NOTICE

Clearance to venting is for single wall vent pipe. If Type L vent is used, clearance may be

reduced to the minimum required by the vent pipe

manufacturer.

C. PROVIDE COMBUSTION AND VENTILATION

AIR. Local and National Codes may apply and should

be referenced.

TABLE 2: DIRECT VENT CONFIGURATION COMPONENTS

Boiler

Model No.

Beckett NX

Oil Burner

Part No.

FORCEOL147 106109-03

FORCEOL189 103369-01

Direct Vent

Conversion Kit

Part No.

106401-01

Adequate combustion and ventilation air must

be provided to assure proper combustion and to maintain safe ambient air temperatures.

Do not install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, fabric softeners, etc.) are used or stored.

D. DIRECT VENT CONFIGURATIONS requires:

1. Beckett NX Burner

2. Direct Vent conversion Kit

3. Double Wall Flex Oil Vent Pipe (FOVP)

FOVP Carton Part No.

100211-02 - 5 ft.

100212-02 - 10 ft.

100213-02 - 15 ft.

100214-02 - 20 ft.

3"3"

AIR INTAKE PIPING

6"6"

AIR INTAKE

PIPING

(REMOVED

FOR CLARITY)

24"

Figure 2B: Direct Vent - Minimum Installation Clearances To Combustible Materials (Inches)

NOTES: 1. Listed clearances comply with American National Standard

ANSI/NFPA 31, Standard for the Installation of Oil Burning Equipment.

2. FORCEOL boilers can be installed in rooms with clearances from combustible material as listed above. Listed clearances cannot be reduced for alcove or closet installations.

FDVS

AIR INTAKE PIPING

DIRECT

VENT

PIPING

3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31

standard.

Page 9

III: PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS

A. REMOVE CRATE.

1. Remove all fasteners at crate skid.

2. Lift outside container and remove all other inside protective spacers and bracing. Remove miscellaneous parts carton.

B. REMOVE BOILER FROM SKID.

1. To reduce the risk of damage to boiler jacket, use the following procedure to remove from skid, see Figure 3:

Step 1. Boiler is secured to base with (4) 5/16" cap

screws, (2) in front and (2) in rear of shipping skid, see Figure 3. Remove all securing hardware.

Step 2. Place wooden block(s) 12" from rear of

skid as shown (one piece 4" x 4" x 16" lg. or two pieces of 2" x 4" x 16" lg.)

Step 3. Insert 1" Sch. 40 pipe handles through leg

hole in front and rear legs. Center end of pipe on wooden blocks as shown in Figure 3.

NOTE: Pipe handles should extend a minimum

of 48" beyond jacket front panel for best

leverage.

Step 4. Using the pipe handles, lift boiler until

adjustable legs are elevated above the deck boards.

Step 5. Remove skid from underneath the boiler.

Step 6. Lower pipe handles until front adjustable

legs touch oor. If necessary, place wooden

blocks under front legs before lowering to provide hand clearance.

Step 7. To lower rear of boiler, tilt unit slightly

forward by pushing on smokebox collar or lift pipes protruding through rear legs until wooden blocks can be removed (see Figure 3). Slowly allow the weight of the boiler to tilt backward

until rear legs rest on oor.

Step 8. If wood block was placed under front legs,

lift pipe handles, remove wooden block and

lower front legs to oor. Remove pipe handles.

CAUTION

Do not drop boiler. Do not bump boiler jacket

against oor.

C. MOVE BOILER TO PERMANENT POSITION

by sliding or walking.

D. PROCEDURE TO OPEN, CLOSE AND

SECURE BURNER SWING DOOR

Throughout this manual you will be instructed to open

and close the burner swing door for various reasons. There is a proper and improper method to closing and securing the burner swing door opened for inspection,

cleaning or eld service.

1. TO OPEN BURNER SWING DOOR (see Figures 4A and 4B).

Step 1. Loosen but do not remove left side latching

hardware (3/8" x 1-3/4" lg. tap bolt).

Figure 3: Packaged Boiler Removal from Skid

Page 10

III: Packaged Boiler Assembly - Trim & Controls (continued)

Figure 4A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured

Step 2. Loosen and remove right side latching

hardware (3/8" x 1-3/4" lg. tap bolt and washer).

Step 3. Remove left side latching hardware (3/8" x

1-3/4" lg. tap bolt and washer).

Step 4. Disconnect burner power cord from

receptacle located in lower right corner of jacket front panel.

Step 5. Door can be swung to the fully open

position, approximately 90° to 120°, with the burner mounted providing that there is 19" of

clearance to the adjacent wall, see Figure 1.

NOTE: If reduced clearance prevents the door

from opening fully, one of the following can provide full access:

a. Burner can be removed to allow full rotation

of door.

b. Door with burner mounted can be lifted

off mounting bracket and set aside during servicing.

c. The door mounting hardware is reversible

from left side hinge (as shipped) to right side hinge.

To reverse hinge arrangement (see Figure

4A):

• Lift door off mounting bracket and set aside.

• Remove mounting bracket and hardware from left side.

• Remove upper jacket front panel retaining screw (5/16" x 1/2" lg. Phillip Pan head machine screw) from right side of door and re-install in vacated upper mounting bracket tapping. Do not tighten.

• Move lower jacket panel retaining screw from right side to left tapping. Do not tighten.

• Rotate door mounting bracket 180°. Insert 5/16" cap screw through top hole in bracket and install in upper vacated jacket hole on right side of door.

• Install second 5/16" cap through bracket hole into lower vacated tapping on right side.

• Tighten both sets of hardware to secure jacket and mounting bracket.

• Lift door and place integral cast hinge pins on door into slotted mounting bracket holes.

2. Perform routine inspection, service or cleaning as necessary.

Page 11

III: Packaged Boiler Assembly - Trim & Controls (continued)

Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)

Page 12

III: Packaged Boiler Assembly - Trim & Controls (continued)

3. TO CLOSE BURNER SWING DOOR (see Figures 4A and 4B):

Step 1. From the fully open position, rotate Burner

Swing Door to the closed position.

Step 2. If necessary, place your right hand under

the burner air tube to lift upward. Lift the door up unto the built-in cast ramp/door rest (protruding from the bottom of the front section casting - see Figure 4A).

Step 3. Use one hand to help hold door in position

by lifting up on rear burner housing or applying pressure directly to the door while re-installing the securing hardware with your opposite hand.

Always install right side latching hardware

 then install left side hinge hardware 

second. Apply additional pressure while hand tightening the hardware as far as possible, then release the pressure.

NOTICE

When securing burner swing door make sure door

is drawn-in equally on both sides.

Step 4. Use a hand wrench to tighten door hardware

and always start with the right side cap  Use an alternating tightening method from right side tap bolt to left side tap bolt to tighten door equally until sealed without applying excessive torque. Never tighten left

side ange bolt rst or tighten either piece of

hardware 100% without using the alternating tightening method described above.

Failure to follow the prescribed procedure could

cause thread damage to casting or a leak in the door seal. If left side tap bolt is tightened before right side tap bolt, right side of door can not be drawn-in to provide an air tight seal, as shown in Figure 4C. Applying excessive torque will only cause thread damage.

E. INSPECT SWING DOOR INSULATION AND

ROPE GASKET.

1. Open burner swing door using procedure previously outlined in Paragraph D of this section.

2. Inspect berglass rope located on the swing door.

The rope must be evenly distributed around the perimeter of the door groove and cannot bunch or overhang. There must not be a gap where the two ends of the rope meet. Repair or replace if the rope is damaged or if there is a gap between the ends.

Figure 4C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed

Page 13

III: Packaged Boiler Assembly - Trim & Controls (continued)

3. Inspect burner swing door insulation for damage and proper type.

By design, cast bars on front section between the

combustion chamber and between the left and right side 2nd and 3rd pass ueway should make an impression in door insulation to seal the chambers.

If insulation is damaged or not of proper type

regarding pockets, it must be replaced.

4. Do not close and secure door at this time, proceed to Field Assembly Details, Paragraph F.

F. FIELD ASSEMBLY OF BOILER TRIM AND

CONTROLS

Open miscellaneous parts carton and remove contents.

Identify the components using the illustrations (see Figure 5) throughout the assembly sequence outlined below as it applies to your installation.

1. Install supply piping and relief valve, refer to Figures 1 and 5.

Step 1. Locate the supply piping supplied with

boiler. Apply thread sealant to all joints prior to assembly. Thread 1½" NPT x 6" long supply nipple into 1½" NPT tapping on the topside of the rear section. Thread 1½" x 1½" x ¾" NPT tee onto 6" nipple. Tighten all joints until watertight and ¾" NPT connection on tee is positioned to allow clearance for relief valve discharge.

Step 2. Locate the relief valve piping supplied

with boiler. Apply thread sealant to all joints prior to assembly. Thread the ¾" NPT street elbow onto tee listed above. Install relief valve into street elbow. Tighten all joints until watertight and relief valve is positioned to allow clearance for discharge. Installation of the relief valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV.

WARNING

Safety 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, plugs or caps.

2. Install Boiler Control

(Hydrolevel HydroStat 3250 Plus)

Step 1. Locate the HydroStat/Harness Assembly.

Refer to the 36” Remote Mounting Kit instructions (Included in the 36” Remote

Mounting Kit, P/N 105288-01) located in

the Misc. Parts Carton. Refer to Paragraph D for Swing Door Hinge placement. Secure HydroStat 3250 Plus control to the hinge side Side Panel with supplied sheet metal screws as shown in Figure 5.

Figure 5: Supply Piping and HydroStat 3250 Plus Control Assembly Details

Page 14

III: Packaged Boiler Assembly - Trim & Controls (continued)

Figure 6: Limit Sensor Insertion

Step 2. Locate (2) 5/8” cable clamps in parts

carton. Secure burner wiring harness to front of jacket right side panel with cable clamps and existing jacket screws at top and mid-point.

Step 3. Locate the sensor (included in the 36”

Remote Mounting Kit). Carefully connect sensor into the HydroStat 3250 Plus circuit board by pressing connector on sensor unit into mating connector on circuit board. Fish the sensor through top knockout; allow adequate slack in sensor cable. Insert sensor into immersion well located in the front section until it rests against the bottom of the well. Secure sensor to immersion well with supplied well cap (included in the 36” Remote Mounting Kit).

Step 4. Locate (2) 3/16” cable clamps in parts

carton. Secure sensor wire to top jacket panel and side jacket panel with cable clamps with self-tapping sheet-metal screws (included) as shown in Figure 5.

Figure 7: Return Injector Piping and

Relief Valve Assembly Details

3. Install return injector piping and relief valve, refer to Figure 7.

Locate the return pipe ttings and injector. Apply

sealant to the 2” NPT injector threads. Insert injector into 2” NPT upper rear tapping on rear section. Thread 2” NPT x 1-1/2” Reducing Elbow onto 2” NPT injector.

NOTE: Based on system return piping and

access to service boiler, see Figures 1, 10A and 10B, predetermine if injector piping orientation is to be positioned for vertical, horizontal left or horizontal right side return piping as shown in Figure 7.

Figure 8: Piping Arrangement for Drain Valve and Indirect Water Heating Return

Page 15

III: Packaged Boiler Assembly - Trim & Controls (continued)

4. Install drain valve, see Figure 8.

Step 1. Apply pipe sealant to both ends of

1-1/4" NPT x 5" lg. nipple. Thread nipple into 1-1/4" NPT lower rear tapping on rear section.

Step 2. Thread 1-1/4" x 1-1/4" x 3/4" NPT tee

on opposite end of 5" lg. nipple installed in Step a.

NOTE: Based on access for servicing

and location of sewer or oor drain, when tightening these ttings, determine if drain

valve is to be located on the left or right side.

Tighten nipple and tee into 1-1/4" NPT

lower rear tapping on rear section until joints are water tight for desired position.

TABLE 3: BAFFLE USAGE

Boiler Model

FORCEOL084 None

FORCEOL115

FORCEOL147

FORCEOL189

P/N 102066-01

P/N 100042-01

Bafe Usage

Pass 3rd Pass

[2]

P/N 100081-01

None

Step 3. Apply sealant to 3/4" NPT thread on

drain valve. Thread into 3/4" NPT tapping on side outlet of tee. Use hex nut portion to tighten valve until water tight.

5. Connect Field Wiring.

Connect the eld wiring from the circulator to

the HydroStat 3250 control. Make the wiring

connections as shown on Figures 27, 28 and 29.

6. Installing stainless steel ueway bafes. Bafe

requirements differ from model to model, see Table 3.

NOTE: Read caution statement before proceeding.

CAUTION

These bafes will generate higher efciencies

and lower stack temperatures. Under certain conditions, a lower gross stack temperature entering the chimney has the potential to be cooled below the dew point and create condensate on interior surfaces. Flue gas condensate is

corrosive, which requires special consideration

and must be addressed immediately. DO NOT install bafes until you have read

Sections VI and VII, completely (venting details).

Install stainless steel bafes provided in

miscellaneous parts carton as follows, refer to Table

3 and Figure 9:

• Model FORCEOL084 - To install ueway bafe in 3rd pass on left side of boiler, hold bafe with word "Left" readable at the top. Slide bafe in ueway until position tab touches ns on left side of 3rd pass ueway. To install ueway bafe in 3rd pass ueway on right side of boiler, hold bafe with word "Right" readable at the top. Slide bafe in ueway until position tab touches ns on

right side of 3rd pass ueway.

• Model FORCEOL115 - To install ueway bafe in 3rd pass on left side of boiler, hold bafe with word “Left” readable at the top. Slide bafe in ueway until position tab touches ns on left side of 3rd pass ueway. To install ueway bafe in 3rd pass ueway on right side of boiler, hold bafe with word “Right” readable at the top. Slide bafe in ueway until position tab touches ns

on right side of 3rd pass ueway. To install

ueway bafe in 2nd pass on left side of boiler, hold bafe with word “Left” readable at the top. Slide bafe in ueway until position tab touches ns on left side of 3rd pass ueway. To install ueway bafe in

2nd pass ueway on right side of boiler, hold

bafe with word “Right” readable at the top. Slide bafe in ueway until position tab touches ns on right side of 3rd pass ueway.

• Models FORCEOL147 and FORCEOL189

To install ueway bafe in 2nd pass ueway on left side of boiler, hold bafe with word "Left" readable at the top. Slide bafe in ueway until position tab touches ns on

right side of 2nd pass ueway. To install

ueway bafe in 2nd pass ueway on right side of boiler, hold bafe with word "Right" readable at the top. Slide bafe in ueway until position tab touches ns on left side of

2nd pass ueway.

NOTE: 2nd and 3rd pass ueway bafe are not

interchangeable.

7. Close the burner swing door and securely seal the door to the boiler front section by reinstalling the hardware and securing the door using procedure previously outlined in Paragraph D of this section.

NOTICE

When securing burner swing door make sure

door is drawn-in equally on both sides.

Page 16

III: Packaged Boiler Assembly - Trim & Controls (continued)

Figure 9: Bafe Orientation in Flueways

Page 17

IV: WATER BOILER PIPING

NOTICE

Failure to pipe boiler as specied in this manual may result in excessive system noise.

A. EVALUATE THE EXISTING WATER

SYSTEM.

Design a piping system and install boiler which will

prevent oxygen contamination of boiler water and frequent water additions.

1. There are many possible causes of oxygen contamination such as:

a. Addition of excessive make-up water as a result

of system leaks.

b. Absorption through open tanks and ttings.

c. Oxygen permeable materials in the distribution

system.

2. In order to insure long product life, oxygen sources must be eliminated. This can be accomplished by taking the following measures:

a. Repairing system leaks to eliminate the need for

addition of make-up water.

b. Eliminating open tanks from the system.

c. Eliminating and/or repairing ttings which allow

oxygen absorption.

d. Use of non-permeable materials in the

distribution system.

e. Isolating the boiler from the system water by

installing a heat exchanger.

WARNING

System supply and return piping must be connected to correct boiler manifolds.

U.S. Boiler Company, Inc. recommends sizing the system circulator to supply sufficient flow (GPM) to allow a 20°F temperature differential in the system. When sizing the system circulator, the most restrictive single zone should be used to determine maximum pressure drop.

CAUTION

Maintain minimum ½ inch clearance from hot water piping to combustible materials.

3. In order to insure long product life, operate boiler at

appropriate ow rate to minimize areas of overheating

a. Design system to ensure that the ow is above the

limit called for in Table 4.

b. Maintain a constant boiler pressure of 12 PSI.

TABLE 4: MINIMUM FLOW RATE

Boiler Model No. Flow Rate (Gal / Min)

FORCEOL084 4.5

FORCEOL115 6.0

FORCEOL147 8.0

FORCEOL189 10.0

WARNING

Do not operate boiler below minimum volumetric

ow rates.

B. CONNECT SYSTEM SUPPLY AND RETURN

PIPING TO BOILER. See Figures 10A and 10B.

Also, consult Residential Hydronic Heating Installation and Design I=B=R Guide.

1. If this boiler is used in connection with refrigeration systems, the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler. See Figure 11. Also, consult Residential Hydronic Heating Installation and Design I=B=R Guide.

2. If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, the boiler piping must be equipped

with ow control valves to prevent gravity circulation

of boiler water during the operation of the cooling system.

3. If an indirect water heater is used, priority zoning can be used. Do not use priority zoning for Hydro-Air Systems. Refer to the Indirect Water Heater Installation, Operating, and Service Instructions for additional information.

4. The FORCEOL is designed to withstand thermal shock

from return water temperatures as low as 100°F, but prolonged return temperatures of below 135°F can cause excessive ue gas condensation and damage

the boiler and/or venting system.

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.) The bypass should be the same size as the supply and return lines with valves located in the bypass and return line as illustrated in Figures 10A and 10B in

order to regulate water ow for maintenance of higher

boiler water temperature.

Page 18

IV: Water Boiler Piping (continued)

Figure 10A: Recommended Water Piping for Circulator Zoned Heating Systems - Supply Side Circulator

Page 19

IV: Water Boiler Piping (continued)

Figure 10B: Recommended Water Piping for Zone Valve Zoned Heating Systems - Supply Side Circulator

Page 20

IV: Water Boiler Piping (continued)

Figure 11: Recommended Piping for Combination Heating and Cooling (Refrigeration) System

WARNING

The use of a low water cut-off device, while not

required unless radiation level is below the boiler,

is highly recommended.

If a low water cut-off is required, it must be

mounted in the system piping above the boiler. The minimum safe water level of a hot water boiler is just above the highest water containing cavity of the boiler; that is, a hot water boiler must be full of water to operate safely.

5. If it is required to perform a long term pressure

test of the hydronic system, the boiler should rst

be isolated from the system 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.

Page 21

V: INDIRECT WATER HEATER PIPING

A. CONNECT INDIRECT DOMESTIC WATER

HEATER PIPING as shown in Figure 12A and 12B.

Also refer to Figure 10A and 10B.

Refer to instructions furnished with Indirect Water

Heater for additional information.

Figure 12A: Indirect Water Heater Piping w/Supply Side Circulator

on Circulator Zoned Heating System

Figure 12B: Indirect Water Heater Piping w/Supply Side Circulator on Zone Valve Zoned Heating System

Page 22



A. CHIMNEY VENTING

1. Chimney venting is an important part of a safe

and efcient oil red appliance system. Contact your local re and building ofcials on specic

requirements for restrictions and the installation of fuel oil burning equipment. In addition, consult with a professional knowledgeable on the requirements of NFPA 31 – Standard for the Installation of Oil-Burning Equipment and NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances.

2. The safe venting of oil red boilers is dependant on

many factors. Some of these factors include:

a. sufcient draft during the entire heating season

to allow for the safe discharge of combustion byproducts and;

b. suitable corrosion protection in the event of

condensing ue gases. Only a trained and qualied contractor may install this product.

3. The FORCEOL can be vented into a reclay tile-

lined masonry chimney that meets requirements outlined in Paragraph 4 below. It can also be vented into a chimney constructed from type L vent or a factory built chimney that complies with the type HT requirements of UL 103. The chimney and

vent pipe shall have a sufcient draft at all times,

to assure safe proper operation of the boiler. See Figure 13 for recommended installation.

WARNING

Do not de-rate the appliance. Failure to re the

unit at it's designed input may cause excessive condensation upon the interior walls of the chimney. In addition, the lower input may not

create enough draft to adequately evacuate the

by-products of combustion.

4. Chimney Inspection – Prior to the installation of any new or replacement fuel burning equipment the

chimney shall be inspected by a qualied installer.

The chimney shall be inspected for integrity as well as for proper draft and condensate control. Some jurisdictions require the use of a liner when changing fuel types. Some jurisdictions require the use of a liner even when the same fuel is used. At a minimum, the chimney shall be examined

by a qualied person in accordance with the

requirements of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid FuelBurning Appliances.

a. Loose Mortar – Loose mortar could be an

indication of a prior history of condensing ue

gases upon the inside walls of the chimney. Colder climates are more susceptible to this

condition. Under no circumstances shall a chimney of this condition be used until it meets the requirements of NFPA 211.

b. Unlined Chimney – Under no circumstances

shall a chimney constructed of brick only be used. Only approved clay liners or listed

chimney lining systems shall be used as specied

in NFPA 31.

c. Abandoned Openings – Openings through the

chimney wall that are no longer used shall be sealed in accordance to NFPA 211. Often abandoned openings are improperly sealed and usually covered by a gypsum wall covering.

d. Clean Chimney – Chimney shall be free of all

loose debris.

5. Draft Regulator – the draft regulator supplied with the boiler must be used with this appliance. Refer to Figures 13 and 14.

B. CHIMNEY CONNECTOR

1. A chimney connector (vent pipe) is used to connect the boiler to the base of the chimney. The chimney connector should be kept as short as possible. The horizontal length of the chimney connector shall not be greater than 10 feet.

NOTE: Secure chimney connector to cast iron

smokebox collar with three (3) #10 x ½" self drilling hex head TEK screws provided in miscellaneous parts carton. Locate screws around perimeter of connector as shown in Figure 13 and approximately ½" in from edge. Use drill with 5/16" hex bit to drive screws through connector and smokebox collar.

DANGER

The chimney and connector shall be inspected annually for signs of debris and corrosion. Loose mortar at the base of the chimney may be a sign of condensate damage to the chimney. A chimney professional shall be contacted immediately to examine the damage and recommend a solution. Long term operation while in this condition may

cause a venting failure and force ue gases into

the living space. If the chimney is to be re-lined use the recommendations in NFPA 31.

2. Type B Chimney Connector - a type B chimney

connector can be used to transmit the ue gases provided ue gas temperature entering the chimney connector is greater than 310°F.

3. Type L Chimney Connector - a type L vent or other suitable material shall be used for a chimney connector if the temperature or exiting temperature

is less than 310°F.

Page 23

VI: Natural Draft Venting (Chimney) (continued)

FIRECLAY TILE LINED CHIMNEY

NOT LESS THAN 8" X 8" X 15'

NOTE: ALL HORIZONTAL VENT PIPE

SHOULD SLOPE UPWARD NOT LESS THAN ONE INCH IN FOUR FEET.

DRAFT REGULATOR

DILUTION AIR

BOILER

(FRONT)

Figure 13: Recommended Vent Pipe Arrangement and Chimney Requirements

SEE

DETAIL 'A'

THIMBLE

SLOPE UP

VENT

SYSTEM

CLEANOUT

APPROX.

120°

AIR GAP

10 O'CLOCK

POSITION

6 O'CLOCK

POSITION

RECOMMENDED SCREW LOCATIONS

FOR CHIMNEY CONNECTORS

2 O'CLOCK

POSITION

Figure 14: Proper and Improper Locations of Draft Regulator

Page 24

VI: Natural Draft Venting (Chimney) (continued)

DANGER

Any signs of condensate seepage at the base of the chimney shall be inspected immediately. The discoloration may be a sign of chimney damage and must be remedied immediately.

C. DRAFT

1. The natural draft generated through a chimney is dependent on several factors including, chimney

height, temperature of ue gases, cross section area

of chimney, chimney wall insulation value, dilution

air and total volume of ue gases, to name a few.

Make sure that the boiler has been running for at least 5 minutes before measuring the draft.

2. Minimum Draft at Breech (Canopy) – The draft induced by a chimney must create at least a pressure

of 0 (zero) inches water column (“ w.c.) at the

pressure tapping on the canopy mounted on rear of boiler (see Figure 15). The pressure at the canopy CANNOT be positive since this could create a

condition that allows ue gas by-products to escape

from the draft regulator. A negative pressure reading up to -.03 inches water column is acceptable for proper operation (see Beckett AFG Burner

Specications, Table 9 at the end of this manual for

more details).

3. Minimum Overre Pressure – The overre

pressure is another piece of information that is often measured, however this should be done for observation purposes only! The breech pressure must be used to qualify the draft condition. See

Table 9 for more details as a guide. Actual draft and

temperature measurements may be different then those values in the table.

D. STACK TEMPERATURE

1. The temperature of the ue gases has a signicant

effect on the amount of draft created in a vertical chimney as well as the propensity to create condensate. The higher the stack temperature, the greater the amount of draft that can be generated. A lower stack temperature not only reduces the amount of draft that can be created but it also increases the

possibility that the ue gases could condense in the

chimney connector or stack.

2. NFPA 31 has information to help the installer make an appropriate choice of venting materials. In some cases a chimney may have to be lined to

create sufcient draft. In other cases, the chimney

may have to be lined to prevent the corrosion of a masonry chimney. Consult with a chimney specialist knowledgeable on the requirements for chimney requirements in your area.

CAUTION

Any doubt on the condition of a chimney or it’s ability to prevent the generation and accumulation

of ue gas condensate, must be relined according

to NFPA 31.

CAUTION

Use the chimney venting tables as a guide. It is highly recommended that any borderline application should result in the relining of the

chimney with a suitable liner that creates sufcient

draft and to protect against corrosion caused by

ue gas condensate.

Figure 15: Smokebox Pressure Tapping for

Checking Draft at Breech

3. Bafes – The efciency of the boiler is based on the insertion of ue bafes supplied with your product. Under no circumstances are other bafes to be used

on this product. Refer to Section III, Paragraph F,

Item 6 for bafe installation. If there is any doubt

on the application of this boiler on the intended

chimney, consult with your local code ofcials. At a minimum, remove the bafes to increase the stack temperature. See Table 9 for temperature differential with bafes IN and OUT. In addition,

the lower the CO temperature.

level the higher the stack

Page 25

VI: Natural Draft Venting (Chimney) (continued)

E. MINIMUM CLEARANCES

WARNING

Remove the bafes if there are any signs

of condensation in the chimney or chimney connector. Consult with your local chimney professional for recommendations.

See Figure 2A for details regarding clearances to

combustibles for the boiler.

Page 26

VII: DIRECT VENTING / AIR INTAKE PIPING

A. GENERAL GUIDELINES

1. Direct Vent system must be installed in accordance with these instructions and applicable provisions of local

building codes. Contact your local re and building ofcials on specic requirements for restrictions

and the installation of fuel oil burning equipment. In addition, for boiler installation in United States, consult with a professional knowledgeable on requirements of NFPA 31- Standard for the Installation of Oil-Burning

Equipment and NFPA 211 Standard for Chimney, Fireplaces, Vents and Solid Fuel-Burning Appliances,

latest editions.

2. In the Direct Vent conguration, all air for combustion is supplied directly to the burner from outdoors, and, ue

gases are vented directly outdoors (thru wall), via Direct Vent System (FDVS), which is a non-positive pressure

vent system termination for oil-red appliances, that

provides an outlet for products of combustion, and, an intake for combustion air in a single concentric terminal.

3. Direct Vent Hood Assembly minimum clearance to combustible material is 0".

4. Maximum wall thickness that FDVS vent termination may be installed through is 12".

This venting system must be installed by a

qualied installer (an individual who has been

properly trained) or a licensed installer. DO NOT locate vent termination where

exposed to prevailing wind. Moisture and ice may form on surfaces around vent termination. To prevent deterioration, surface must be in good repair (sealed, painted etc.).

DO NOT locate vent termination where petroleum distillates, CFC's, detergents, volatile vapors or any other chemicals are present. Severe boiler corrosion and failure will result.

DO NOT locate vent termination under a deck.

5. Locate the vent terminal so vent pipe is short and direct,

WARNING

and, at the place on exterior wall that complies with

the minimum distances as specied in Figure 16 and

listed as follows. The vent termination must be located (as measured to the bottom of vent terminal):

a. Not less than 12" above nished grade or expected

snow accumulation line whichever is greater.

b. Not less than 3 ft above any forced air inlet located

within 10 ft.

Figure 16: Vent Terminal Location

Page 27

VII: Direct Venting / Air Intake Piping (continued)

c. Not less than 4 ft from any door, window or gravity

air inlet.

d. Not less than 7 ft above grade when located above

public walkway.

e. Not less than 3 ft (as measured to side of vent

termination) from an inside corner of an L-shaped structure.

f. Not less than 1 ft from the nearest surface of the

terminal to a roof soft.

g. Not directly above, or, not less than 6 ft horizontally

from an oil tank vent or gas meter.

h. Not less than 2 ft from nearest surface of terminal

to an adjacent building.

B. INSTALLATION OF THE VENT HOOD TERMINAL

(see Figures 17, 18, 19 and 20)

1. Inspect Direct Vent Conversion Kit Carton for damage. DO NOT install if any damage is evident.

2. Direct Vent Conversion Kit Carton includes:

• Direct Vent Hood Assembly (consists of Vent Hood

Body and Combustion Air Tee) – 1 pc

• Backing Plate – 1 pc

• Vacuum Relief Valve VRV-4 – 1 pc

• Hardware Bag (includes high temperature sealant,

fasteners and inner pipe clamps) – 1 pc

• Appliance Adapter – 1 pc

• Appliance Clamp Halves – 2 pcs

• Cover Sleeve Assemblies – 2 pcs

• Cover Ring Assemblies – 2 pcs

3. Remove vent system components from carton and set aside.

4. Separate the vent hood tee from the vent hood body and set aside for later use.

5. After determining the location of the venting system termination, cut the square hole in the wall sized

according to “L” dimension in Table 5, see Figure 17.

6. Wood or vinyl siding should be cut, so that vent hood base plate mounts directly on the wallboard to provide stable support. If siding thickness exceeds ½”, use a spacer bar or board behind the vent hood mounting

(base) plate. See Figure 18.

a. Seal the backside of the vent hood base plate around

the outer pipe of the vent hood with a bead of hightemperature silicone sealant (provided in Bagged Hardware).

b. Mount the vent hood body from outside, through

the wall, keeping the outer pipe centered in the hole.

c. Fasten the vent hood body to the outside wall with

appropriate fasteners (installer provided).

TABLE 5: WALL CUTOUT DIMENSIONS

Boiler Model

No.

FORCEOL147 FORCEOL189

Direct Vent Conversion

Kit Part No.

106401-01 8¼

"L" Dimension

Figure 17: Wall Cutout Dimensions

Figure 18: Vent Hood Body Installation

d. Seal the edges of the vent hood base plate to the wall

with a high-temperature silicone sealant (provided in Bagged Hardware).

e. While inside, position the backing plate over the

outer pipe and fasten to inside wall with appropriate fasteners (installer provided).

(Inch)

Page 28

VII: Direct Venting / Air Intake Piping (continued)

D. INSTALLING THE FLEX OIL VENT PIPE

FROM THE VENT TERMINATION TO THE BOILER FLUE OUTLET

1. The venting system (vent pipe and all connectors)

2. A vent pipe connector, designed for positive pressure

Figure 19: Combustion Air Tee

Assembly Installation

C. INSTALLATION OF VENT HOOD TEE

1. Assemble the vent hood tee body to the vent hood outer pipe, and, rotate the tee, so air intake inlet collar is in

the desired position. See Figure 19.

2. Attach the vent hood tee body to the vent hood outer pipe with at least tree sheet metal screws (installer provided).

NOTE: The tee may be rotated into any position so that

the collar is in a convenient orientation.

3. After completing assembly of the exible double

wall insulated vent pipe to the vent termination inner pipe (see Figure 20 and the following Steps), apply the supplied high temperature sealant to seal around the inner pipe protrusion thru the vent tee cover pan, around the joint between the vent tee collar and the vent tee body, and, seal or tape the joint between the vent termination outer pipe and the vent tee body.

3. Support the vent pipe at intervals no greater than three

4. Allow sealant to cure at least one hour before ring

5. Route the vent pipe from the vent termination to the

6. Maximum length of exible oil vent pipe is 20 ft. The

7. Verify that ex vent pipe diameter and vent termination

Table 6).

shall be installed in accordance with the applicable provisions of any local codes, and, in United States, requirements of NFPA 31- Standard for the Installation

of Oil-Burning Equipment and NFPA 211 Standard for Chimney, Fireplaces, Vents and Solid Fuel-Burning Appliances, latest editions.

venting, shall be supported for the design and weight of material employed, to maintain clearances, prevent physical damage and separation of joints. All joints MUST BE sealed, for positive vent pressure, to prevent

ue gas leakage into the structure.

(3) feet apart using perforated metal strap or other non-combustible supports.

boiler.

boiler using the minimum number of bends possible. The last horizontal section of the vent pipe should have a slight downward slope from the boiler to the vent termination. For clearances to combustible materials refer to Figure 2B.

vent pipe is also available pre-cut in 5 ft, 10 ft and 15 ft increments.

inner pipe diameter correspond to a particular direct

vent conguration FORCEOL boiler model (see

Figure 20: FDVS Component Breakdown

Page 29

VII: Direct Venting / Air Intake Piping (continued)

TABLE 6: FLEX VENT / VENT TERMINATION PIPE DIAMETERS

Boiler Model No.

FORCEOL147

FORCEOL189

NOTE: * The model specic Direct Vent (FDVS) Kit Cartons contain adapters (reducers) (see Table 6) to connect boiler ue outlet

collar to vent pipe.

Boiler Flue Outlet

Collar OD (Inch)

6 5 6 to 5

Vent Hood Inner Pipe

Diameter (Inch)

Flex Oil Vent Pipe

Inner Pipe Diameter

(Inch)

* Flue Outlet Collar to

Vent Pipe Adapter (Inch)

Figure 21: Appliance Adapter Installation

E. CONNECTING APPLIANCE ADAPTER TO

BOILER FLUE OUTLET COLLAR

(See Figure 21)

1. Apply a bead of supplied high temperature sealant to

boiler ue outlet collar approximately 1" from collar

end.

2. Remove any oil and grease from inside of supplied Appliance (Boiler Flue Outlet) Adapter, and, apply a bead of high temperature sealant to inside of the adapter, ½" from end.

3. With twisting motion, assemble the appliance adapter

onto boiler ue outlet collar.

4. Using a mallet and a block of wood, carefully tap the adapter onto the outlet collar. Insure no damage is done

to the adapter and the ue outlet collar.

5. Assemble supplied adapter clamp halves with 5/16-18

bolts and square nuts; install the adapter clamp onto the appliance adapter and tighten securely.

6. If required, install anchoring screws (installer provided)

thru four holes in the clamp into the ue outlet collar.

7. Apply sealant around the adapter end mated to the ue

outlet collar.

8. Install supplied 3/8” sampling port plug screw hand

tight into the adapter sampling port.

9. After initial boiler start-up and burner testing/ adjustment are completed, apply high temperature

sealant under the head of sampling port plug screw, and, install the screw in the sampling port tightening securely.

F. CONNECTING FLEX OIL VENT PIPE TO

APPLIANCE ADAPTER AND DIRECT VENT TERMINATION

1. Flexible double wall oil vent pipe is available pre-cut from 5 ft to 20 ft long. If necessary, the vent pipe may be cut to required length with a hacksaw or cutoff saw.

CAUTION

Use safety glasses and other appropriated safety gear when cutting the vent pipe.

2. The double wall exible vent pipe consists of the

smaller inner corrugated stainless steel pipe and larger

corrugated aluminum pipe, separated by berglass

insulation layer.

Page 30

VII: Direct Venting / Air Intake Piping (continued)

7. Apply sealant; rstly, between the stop bead and

8. Assemble supplied inner pipe clamp halves with

9. Remove any oil and grease from inside of each end

Figure 22: Vent Pipe Assembly to Vent Termination

Inner Pipe and Appliance Adapter

10. Apply a thick bead of sealant to inside of each end

11. Firstly, push one end of the inner vent pipe onto the

CAUTION

The inner and outer pipe ends may have sharp burrs. Use gloves, while handling, compressing or expanding the vent pipe.

3. Pull outer vent pipe back 1” to 2” from end of inner

vent pipe and remove insulation; rstly, at vent

pipe end to be connected to the vent termination; secondly, at vent pipe end to be connected to the appliance adapter. See Figure 22.

4. Install supplied Cover Sleeve Assembly onto each end of outer vent pipe, and, move the assembly

a few inches back from the end; rstly, at vent

pipe side to be connected to the vent termination; secondly, at vent pipe side to be connected to the appliance (boiler outlet collar) adapter. See Figure

22.

5. Slide supplied Cover Rings; rstly, over stop bead

on vent termination inner pipe; secondly, over stop bead on appliance adapter. See Figure 22.

6. Remove any oil and grease from the end of vent termination inner pipe, and, from the end of the appliance adapter.

12. Tighten the inner pipe clamp bolts at both vent pipe

13. Starting with vent termination end, slide the cover

14. If the appliance collar is within less than 18" of

15. To maintain vent pipe 1" clearance to combustible

retainer bead at the end of the vent termination inner pipe; secondly, between the stop bead and retainer bead at the end of the appliance adapter. See Figure

23.

1/4-20 bolts and square nuts; position the inner pipe clamps ¼” from the end of inner vent pipe, on vent pipe opposite ends.

of the inner vent pipe.

of the inner vent pipe, ½” from pipe end, working the sealant into the inner vent pipe corrugations. See Figure 23.

vent termination inner pipe, all the way up to the stop bead. Secondly, push the opposite end of the inner vent pipe onto the appliance adapter, all the way up to the stop bead.

ends, until clamp halves are within 1/8” apart. See

Figure 24.

sleeve assembly and the cover ring together to engage the ring in the groove of the sleeve, then, tighten the built-in cover sleeve clamp. Repeat above steps at the boiler end. See Figure 24.

combustible material, wrap minimum 1-1/2" thick

berglass insulation (installer provided).

material, wrap minimum 1-1/2" thick berglass

insulation (installer provided) around the exposed portion of the vent termination inner pipe and secure with adhesive-backed aluminum foil tape (installer provided).

Figure 23: Vent Pipe Ends, Vent Termination and Appliance Adapter Sealing

Page 31

VII: Direct Venting / Air Intake Piping (continued)

DO NOT reduce size of air intake pipe.

3. Remove burner from carton. Secure burner to boiler

4. Remove knockout for 4" vent pipe collar from

5. Start at burner and work towards Direct Vent

6. Procure a 2-ft section of 4" diameter galvanized

7. Insert one end of the vent pipe thru the outside

8. Secure the pipe to collar with at least (3) sheet metal

WARNING

with mounting hardware included with burner swing door. See Figure 26.

burner cover. See Figure 26.

termination air intake.

single wall vent pipe, cut off the crimped pipe end below stop bead.

air duct bracket opening and rmly push onto the

outside air adapter collar.

screws (installer provided) evenly spaced around the collar.

Figure 24: Vent Pipe Assembly to Vent

Termination Inner Pipe & Appliance Adapter

G. INSTALLING THE AIR INTAKE PIPING FROM

DIRECT VENT TERMINATION TO BURNER OUTSIDE AIR ADAPTER

1. Use 4" diameter galvanized single wall vent pipe

and ttings, available at most heating distributors,

to connect burner outside air adapter to Direct Vent Termination air intake collar. See Figure 25.

2. Maximum air intake pipe length is 40 equivalent feet.

NOTE: 90° elbow is equivalent to 5 linear feet.

NOTICE

It is essential to ensure reliable operation that combustion air joints are air tight and that VRV is located as close to the burner as possible.

9. Install supplied vacuum relief valve tee assembly,

crimped end down, into the opposite end of vent pipe.

10. Secure the tee to the pipe with at least (3) sheet metal screws (installer provided) evenly spaced.

11. Remove the vacuum relief valve gate assembly from the tee.

Figure 25: Install Air Intake Piping and Vacuum Relief Valve

Page 32

VII: Direct Venting / Air Intake Piping (continued)

12. Assemble the vacuum relief valve balance weight onto the gate. Refer to the vacuum relief valve manufacturer’s instructions for details.

13. Mount the assembled vacuum relief valve gate with balance weight into the tee and fasten with a screw and nut in collar tabs. To insure proper operation, the gate must be level across the pivot point and plumb. Refer to the vacuum relief valve manufacturer’s instructions for details.

14. Install remainder of air intake piping to Direct Vent Termination air intake collar, securing each joint with at least (3) sheet metal screws (installer provided) evenly spaced.

15. Maintain ¼” per foot slope in horizontal run to air intake of Direct Vent Termination.

16. Support the air intake piping, as required, using perforated metal strap or other supports.

17. Refer to Burner Manufacturer's Manual for addition information.

Figure 26: Oil Burner Installation (NX Beckett shown)

Page 33

VIII: ELECTRICAL

DANGER

Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off.

WARNING

Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.

Each boiler must be protected with a properly sized fused disconnect.

Never jump out or make inoperative any safety or operating controls.

A. GENERAL

1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/ NFPA 70.

2. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.

3. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions.

4. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes.

5. Use armored cable (BX) over all exposed line voltage wiring.

6. If an indirect domestic water heater is used, use priority zoning. Do not use priority zoning for Hydro-Air Systems.

7. Wiring should conform to Figures 27, 28, 29 and 30.

B. INSTALL A ROOM THERMOSTAT on an

inside wall about four feet above oor. Never install

thermostat on an outside wall or where it will be

inuenced by drafts, hot or cold water pipes, lighting xtures, television, rays of the sun or near a replace.

Keep large furniture away from thermostat so there will be free movement of room air around this control.

Heat Anticipator in Thermostat should be set to match

the requirements of the control to which it is connected.

See Figures 27, 28 and 29 for desired system and

heat anticipator setting. If system tends to overheat above the thermostat's temperature setting, reduce heat anticipator setting by .1 or .2 amps. If system tends to short cycle without reaching desired room temperature, increase heat anticipator setting by .1 or .2 amps.

Page 34

REFER TO FIGURE 30 FOR

SCHEMATIC WIRING DIAGRAM

OF APPROPRIATE BURNER AND

OIL PRIMARY CONTROL OPTION

VIII: Electrical (continued)

Figure 27: Schematic Wiring Diagrams, Cold Start Control with Beckett AFG Burners

Page 35

REFER TO FIGURE 30 FOR

SCHEMATIC WIRING DIAGRAM

OF APPROPRIATE BURNER AND

OIL PRIMARY CONTROL OPTION

VIII: Electrical (continued)

Figure 28: Schematic Wiring Diagram, Cold Start Control with Beckett NX Burners

Page 36

VIII: Electrical (continued)

Figure 29: Schematic Wiring Diagrams HydroStat 3250 Control with Beckett AFG Series Burners

Page 37

VIII: Electrical (continued)

NOTE: APPLY THIS BURNER

SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO Figures 27 and 28

NOTE: APPLY THIS BURNER SCHEMATIC TO APPROPRIATE STEAM OR WATER BOILER CONTROL SCHEMATIC, REFER TO Figure 28

Figure 30: Schematic Wiring Diagrams

Page 38

IX: OIL PIPING

A. GENERAL

1. Use exible oil line(s) so the burner swing door

can be opened without disconnecting the oil supply piping.

2. A supply line fuel oil lter is recommended as a minimum for all ring rates but a pleated paper fuel oil lter is recommended for the ring rates below

1.0 GPH to prevent nozzle fouling.

3. Use Flared ttings only. Cast iron ttings cannot be

used.

NOTICE

Do not use compression ttings.

Oil piping must be absolutely airtight or leaks or loss of prime may result. Bleed line and fuel unit completely.

Refer to your local jurisdictions regarding any special considerations for fuel supply

requirements. In addition, refer to NFPA 31,

Standard for the Installation of Oil-Burning Equipment.

4. Use of a high efciency micron lter (Garber or equivalent) in addition to a conventional lter is

highly recommended.

5. Piping used to connect the oil burner to the oil

supply tank shall not be smaller than 3/8" iron pipe or 3/8" OD copper tubing. Copper tubing shall have

a .032" minimum wall thickness.

WARNING

Under no circumstances can copper with sweat style connectors be used.

NOTICE

Some jurisdictions require the use of a fusible

shutoff valve at the tank and/or the burner. In

addition, some jurisdictions require the use of a

fusible electrical interlock with the burner circuit.

Check your local Codes for special requirements.

B. SINGLE PIPE OIL LINES

1. Standard burners are provided with single-stage 3450 RPM fuel units with the bypass plug removed for single-pipe installations.

2. The single-stage fuel unit may be installed singlepipe with gravity feed or lift. Maximum allowable lift is 8 feet. See Figure 31.

3. Fuel Oil Line Deaerator – On many occasions a leaky oil delivery line can introduce air into the fuel oil supply system. This often creates a rough starting condition and can create a burner lockout

state. In addition to xing the leak, a fuel line

deaerator can be installed to eliminate air. The single line from the fuel tank is connected to the deaerator. The burner pump must be connected to the deaerator as a two pipe system. Follow the oil pump manufacturer’s recommendations for conversion to a two pipe system.

Figure 31: Single Pipe Oil Line

Page 39

IX: Oil Piping (continued)

C. TWO PIPE OIL LINES

1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table

7 (two-stage) and Table 8 (single-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch

OD tubing for both suction and return lines. Refer to Figure 32.

2. Follow the oil pump manufacturer’s recommendations on the proper connections for a two pipe system. Some manufacturers require the insertion of a bypass plug.

TABLE 7: TWO-STAGE UNITS (3450 RPM) - TWO PIPE SYSTEMS

Maximum Length of Tubing

Lift "H"

0' 93' 100'

2' 85' 100'

4' 77' 100'

6' 69' 100'

8' 69' 100'

10 52' 100'

12' 44' 100'

14' 36' 100'

16' 27' 100'

18' --- 76'

"H" + "R" (See Figure)

3/8" OD

Tubing (3 GPH)

1/2" OD

Tubing (3 GPH)

3. Under no circumstances is a manual shutoff valve to be located on the return line of a two pipe system. Accidental closure of the return line will rupture the oil pump seals.

TABLE 8: SINGLE-STAGE UNITS (3450 RPM) - TWO PIPE SYSTEMS

Maximum Length of Tubing

Lift "H"

0' 84' 100'

1' 78' 100'

2' 73' 100'

3' 68' 100'

4' 63' 100'

5' 57' 100'

6' 52' 100'

7' 47' 100'

8' 42' 100'

9' 36' 100'

10' 31' 76'

11' 26' 100'

12' 21' 83'

13' --- 62'

14' --- 41'

"H" + "R" (See Figure)

3/8" OD

Tubing (3 GPH)

1/2" OD

Tubing (3 GPH)

Figure 32: Two Pipe Oil Lines

Page 40

X: SYSTEM START-UP

WARNING

All boilers equipped with burner swing doors have a potential hazard which can cause severe property

damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler

to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing door fastener

completely when service is completed. In addition, the burner power cord will have to be disconnected from the receptacle in the front jacket.

A. ALWAYS INSPECT INSTALLATION

BEFORE STARTING BURNER.

1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to Installation Instructions contained in this manual.

2. Conrm all electrical, water and oil supplies are

turned off at the source and that the vent is clear from obstructions.

WARNING

Completely read, understand and follow all instructions in this manual before attempting start up.

B. FILL HEATING SYSTEM WITH WATER.

NOTICE

It is important to properly remove the oil and dirt from the system. Failure to clean the system can result in clogged air vents, circulator damage and seized zone valves.

CLEAN HEATING SYSTEM if boiler water is

dirty.

Refer to Maintenance and Service Instructions Section

of this manual for proper cleaning instructions for water boilers.

1. HOT WATER BOILERS. Fill entire heating system with water and vent air from system. Use the following procedure on a series loop or multizoned system installed as per Figure 10A and 10B,

to remove air from system when lling:

a. Close full port ball valve in boiler system piping.

b. Isolate all zones by closing zone valves or shut-

off valves in supply and return of each zone(s).

c. Attach a hose to vertical purge valve in boiler

system supply piping up stream from the full port ball valve.

(NOTE - Terminate hose in ve gallon bucket at

a suitable oor drain or outdoor area).

d. Starting with one zone at a time, open zone valve

or shut-off valve in boiler supply and return piping.

e. Open purge valve.

f. Open shut-off valve in cold water supply piping

located between the air scoop and expansion tank.

g. Allow water to overow from bucket until

discharge from hose is bubble free for 30 seconds.

h. When zone valve is completely purged of air,

close zone valve or shut-off valve. Open zone valve to the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves.

i. Close purge valve, continue lling the system

until the pressure gauge reads 12 psi. Close shutoff valve in cold water supply piping.

WARNING

The maximum operating pressure of this boiler is posted on the ASME Data Label located on the top of the boiler. Never exceed this pressure. Do not plug relief valve.

NOTICE

If make-up water line is equipped with pressure reducing valve, system will automatically ll to 12 psi. Follow ll valve manufacturer's instructions.

j. Open full port ball valve in boiler system piping.

k. Remove hose from purge valve.

l. Conrm that the boiler and system have no water

leaks.

m. It may be necessary to clean the air vent

assembly after a few days of operation.

C. CHECK CONTROLS, WIRING AND

BURNER to be sure that all connections are tight and

burner is rigid, that all electrical connections have been

completed and fuses installed, and that oil tank is lled

and oil lines have been tested.

Page 41

X: System Start-Up (continued)

D. ADJUST CONTROL SETTINGS with burner

service switch turned “ON”.

1. SET ROOM THERMOSTAT about 10°F below

room temperature.

2. PRESS RED RESET BUTTON on burner primary control, hold for ten (10) seconds and release to reset the control.

3. CHECKOUT

Put the system into operation and observe at least

one complete cycle to make sure that the controller operates properly. See Troubleshooting Section to use LED to assist in determining system operation.

E. CHECK / ADJUST OIL BURNER BEFORE

STARTING.

Natural Vent Applications:

1. Beckett AFG Burners

a. Verify nozzle size, head size, gun setting, and

positioning of electrodes. This information is shown in Figure 33, and Beckett AFG Burner

Specications, Table 9.

b. Inspect Beckett head setting on left side of

burner housing by insuring the blue line MD(V1) or the line on the label MB(L1) are aligned, readjust if necessary. Refer to Figure 33 and

Table 9 at the end of this manual.

c. Check burner air band and air shutter settings.

Readjust if necessary, see Beckett AFG Burner

Specications, Table 9 at the end of this manual.

d. OPEN ALL SHUT-OFF VALVES in the oil

supply line to the burner.

e. ATTACH A PLASTIC HOSE TO FUEL PUMP

VENT/BLEED FITTING and place the other hose end into an empty container to catch the oil.

f. SLIGHTLY OPEN FLAME OBSERVATION

PORT COVER on burner swing door, enough to insert draft gauge probe later.

Direct Vent Applications:

2. Beckett NX Burners

a. Verify nozzle size, gun setting and positioning of

electrodes. See Figures 34 and 36 and Beckett

NX Burner Specications, Table 10 at the end of

this manual.

b. Remove burner cover by loosening the four

thumb screws and set aside.

c. Disconnect the copper oil connector tube from

nozzle line.

d. Loosen the two screws securing igniter-retaining

clips and rotate both clips to release the igniter baseplate. The igniter should pop-up and would be supported by the prop spring.

e. Loosen the two screws securing the rear door,

then swing to the right and down.

f. Loosen splined nut.

g. Lift up the igniter baseplate and simultaneously

remove nozzle line assembly from burner by drawing it straight back out the rear door opening. Be careful not to damage the electrodes or insulators while handling.

h. Check electrodes to comply with dimensions

shown in Figure 34. For adjustment, loosen the electrode clamp screw and slide/rotate electrodes as needed. Securely re-tighten the clamp screw

when nished.

i. Check retention head alignment. Cad cell

sighting holes in the throttle cup and retention head must line up, so the cad cell can see the

ame. Make sure that, the “stamped key” in the retention head collar lines up with the “keyway”

in the nozzle adapter, when mounting the retention head. See Figure 35.

j. To re-install the nozzle line assembly, reverse

procedure outlined in steps f thru b.

k. Upon reinstallation of the nozzle line assembly,

check that head/air plate setting number pointer lines up with a number on the scale, which matches a value shown in Table 10 for a particular boiler/burner model.

The zero calibration has been factory set; the

upper left acorn nut locks retention head at

“0” position. If the zero calibration has to be

reset, follow the adjustment procedure, outlined

at “Prepare Burner & Site” section of Beckett

Model NX Oil Burner Instruction Manual, Form Number 610BNX. Make sure the retention head is securely against the stops in the retention ring,

when the adjustment plate pointer is at “0”.

l. The rear door must be kept tightly closed upon

reinstallation of the nozzle line assembly.

m. Loosening the splined nut and lower acorn nut,

and, turning the adjustment screw, either forward or, rearwards, will adjust the head/air plate. DO NOT LOOSEN UPPER LEFT ACORN NUT, which locks zero head/air setting. See Figure 36.

n. OPEN ALL SHUT-OFF VALVES in the oil

supply line to the burner.

o. ATTACH A PLASTIC HOSE TO FUEL PUMP

VENT/BLEED FITTING and place the other hose end into an empty container to catch the oil.

p. SLIGHTLY OPEN FLAME OBSERVATION

PORT COVER on burner swing door, enough to insert draft gauge probe later.

Page 42

X: System Start-Up (continued)

Figure 33: "L1" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)

Page 43

X: System Start-Up (continued)

WARNING

Very hot ue gases come out of ame observation

port cover hole when boiler is operated with port cover open. Always wear proper eye protection.

Figure 34: Electrode Tip Gap and Spacing

4. Close vent tting and burner ame should start

immediately after prepurge is completed. Prepurge

prevents burner ame until 15 seconds has elapsed

after initial power is applied to burner. During prepurge the motor and igniter will operate but the oil valve will remain closed. Refer to Oil Primary Control Instructions for more details.

5. Adjust oil pressure.

a. When checking a fuel unit's operating pressure, a

reliable pressure gauge may be installed in either the bleeder port or the nozzle port. Refer to Figure 37.

b. Locate oil pressure adjusting screw and turn

screw to obtain proper pump pressure, refer to

Tables 9 and 10 at the end of this manual.

c. To check the cut-off pressure, deadhead a reliable

pressure gauge onto the copper connector tube attached to the nozzle port. Run the burner for a short period of time. Shut the burner off. The pressure should drop and hold.

d. Turn "OFF" the burner. Remove the pressure

gauge and install port/bleeder plug and/or reconnect the nozzle port line and tighten. Start the burner again.

Figure 35: Retention Head/Throttle Cup Alignment

Figure 36: Head/Air Adjustment Plate Assembly

F. START OIL BURNER.

1. Open vent tting on fuel pump.

2. PRESS RED RESET BUTTON on primary control, hold for ten (10) seconds and release to reset primary control.

3. TURN ‘ON’ BURNER service switch and

allow burner to run until oil ows from vent tting in a SOLID stream without air bubbles for

approximately 10 seconds.

NOTE: For Primary Control "Pump Priming

Cycle" details, see Paragraph I, No. 2., Step a., Item ii .

G. ADJUST OIL BURNER WHILE

OPERATING. (ame present)

1. ADJUST DRAFT REGULATOR for a draft of zero inches (water gauge) in the canopy (see Figure

15) after chimney has reached operating temperature

and while burner is running (at least ve minutes).

See Table 9 at the end of this manual for additional

details.

Figure 37: Adjusting Fuel Pump Pressure

Page 44

X: System Start-Up (continued)

2. READJUST THE AIR DAMPER SETTING (Air Band/Air Shutter/Air Gate) on burner for a

light orange colored ame while the draft in the

canopy is zero inches water column ("w.c.). Use a smoke tester and adjust air for minimum smoke (not to exceed #1) with a minimum of excess air. Make

nal check using suitable instrumentation to obtain

a CO2 of 11.5 to 12.5% with draft of zero inches water column ("w.c.) (water gauge) in canopy.

These settings will assure a safe and efcient operating condition. If the ame appears stringy instead of a solid re, try another nozzle of the same

type. Flame should be solid and compact. After all adjustments are made recheck for a draft of zero inches water column ("w.c.) in the canopy. Replace plug at completion.

See Table 9 (at the end of this manual) for details

regarding the overre pressure when bafes are both

installed and removed.

NOTE: Paragraph G, Step 1 MUST BE repeated every

time the Air Damper Setting is readjusted.

3. ONLY READJUST THE HEAD / TURBULATOR SETTING, if necessary.

Beckett AFG Burners

a. FORCEOL084 through FORCEOL147

Beckett MB(L1 & L2) Head burners have a xed

head which are non-adjustable.

b. FORCEOL189:

Beckett MD(V1) (variable) Head burners have

the ability to control air by moving the head. It might be necessary to move the head forward or back one position at a time to optimize the smoke and CO2 readings. See Figure 33.

Beckett NX Burners

Move the Head/Air Setting forward or back one

position at a time to optimize the smoke and CO2 readings. See Figure 36.

NOTE: Step outlined in Paragraph G, Steps 1 and 2

above MUST BE repeated every time the Head/ Turbulator or air Damper Setting is readjusted.

WARNING

DO NOT loosen or remove any oil line ttings while burner is operating.

4. FLAME FAILURE

The FORCEOL boiler controls operate the burner

automatically. If for unknown reasons the burner

ceases to re and the reset button on the primary

control has tripped, the burner has experienced ignition failure. Refer to Oil Primary Control features, Paragraph I, Step 2 of this section and Section XIV, Troubleshooting, Paragraph B. If the failure re-occurs, call your heating contractor immediately before pressing the reset button.

WARNING

DO NOT attempt to start the burner when excess oil has accumulated, when the boiler is full of vapor, or when the combustion chamber is very hot.

5. CAD CELL LOCATION AND SERVICE

The burner is supplied with a cadmium sulde ame

detector mounted at the factory, mounted on the

bottom of the electronic ignitor. See Figure 38. To

service cad cell or to replace the plug in portion, swing open the ignitor. After service is complete, be sure to fasten down the ignitor.

H. CHECK FOR CLEAN CUT OFF OF

BURNER.

1. AIR IN THE OIL LINE between fuel unit and nozzle will compress when burner is on and will expand when burner stops, causing oil to squirt from nozzle at low pressure as burner slows down and causing nozzle to drip after burner stops. Usually cycling the burner operation about 5 to 10 times will rid oil line of this air.

2. IF NOZZLE CONTINUES TO DRIP, repeat Paragraph H, Step 1 above. If this does not stop the dripping, remove cut-off valve and seat, and wipe both with a clean cloth until clean, then replace and readjust oil pressure. If dripping or after burn persist replace fuel pump.

I. TEST CONTROLS.

1. Check thermostat operation. Raise and lower thermostat setting as required to start and stop burner.

WARNING

Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and high limit control.

Page 45

X: System Start-Up (continued)

Figure 38: Cad Cell Location

2. VERIFY OIL PRIMARY CONTROL FEATURES using procedures outlined in

Instructions furnished with control or instructions as follows:

a. GeniSys 7505 Control Features, see Figure 39.

i. The GeniSys 7505 is a microprocessor-

based control. The indicator light provides diagnostic information for lockout, recycling and cad cell status. There is a manual reset button to exit the Lockout Mode.

ii. Pump Priming Cycle: To facilitate purging

air from the oil lines and lters, the 7505 can

be placed in a purge routine by:

• After the burner starts, press and hold the

reset button for 15 seconds until the yellow light turns on. This indicates that the button has been held long enough.

• Release the reset button. The yellow

light will turn off and the burner will start up again.

• At burner start up, click the reset button

while the igniter is till on. This will transition the control to a dedicated Pump Prime mode, during which the motor, igniter, and valve are powered for four (4) minutes. The yellow light will be

on.

• At the end of four (4) minutes, the yellow

light will turn off and the control will automatically return to standby mode.

iii. Limited Recycle: This feature limits the

number of recycle trials (for each call for heat) to a maximum of three trials. If

the ame is lost three times and does not

successfully satisfy a call for heat, the 7505 locks out.

Figure 39: GeniSys 7505 Oil Primary Terminals,

LED's and Reset Button

iv. Limited Reset (Restricted Mode): In order

to limit the accumulation of unburned oil in the combustion area, the control can only be reset three times. The reset count returns to zero each time a call for heat is successfully completed.

v. T-T Jumper: Select models have pre-

installed T-T jumper. DO NOT remove jumper.

NOTE: DO NOT remove "T-T" jumper unless

wiring diagram indicates a direct connection from thermostat and/or tankless heater HydroStat 3250 control to the oil burner primary control's "T-T" terminal. Refer to appropriate wiring diagram, see Figures 27

and 28.

vi. Diagnostic LED: The indicator light on oil

primary control provides lockout, recycle and cad cell indications as follows:

• Flashing at 1 Hz (½ second on, ½ second

off): system is locked out or in Restricted Mode.

• Flashing at ¼ Hz (2 seconds on, 2 seconds

off): control is in Recycle Mode.

• On: cad cell is sensing ame.

• Off: cad cell is not sensing ame.

Page 46

X: System Start-Up (continued)

vii. Cad Cell Resistance Check: For proper

operation it is important that the cad cell resistance is below 1600 ohms. During a normal call for heat, the cad cell leads can be unplugged from the control and the resistance measured with a meter in the conventional way.

Conduct these tests with ame present, see

chart below.

Flame Detection Range

Normal (0 - 1600 ohms)

Limited (1600 ohms to lockout)

3. CHECK OIL PRIMARY CONTROL

CAUTION

Due to the potential hazard of line voltage, only a trained, experienced service technician should perform the following safety checks.

This control contains no eld-serviceable parts.

DO NOT attempt to take it apart. Replace entire control if operation is not as described.

a. Preliminary Steps

• Check wiring connections and power supply.

• Make sure power is on to the controls.

• Make sure limit control is closed.

• Check contacts between ignitor and the

electrodes.

• Check the oil pump pressure.

• Check the piping to the oil tank.

• Check the oil nozzle, oil supply and oil lter.

b. Check Safety Features

Safe Start:

• Place a jumper across cad cell terminals.

• Follow procedure to turn on burner. Burner

must not start, indicator light turns on and control remains in Idle Mode.

• Remove jumper.

c. Simulate Ignition or Flame Failure:

• Follow procedure to turn on burner.

• Check cad cell resistance. If resistance is

below 1600 OHMS and burner runs beyond safety cut-out time, cad cell is good.

• If safety switch shuts down burner and resistance is above 1600 OHMS, open line

switch to boiler. Access cad cell under ignitor,

clean face of cad cell and see that cell is

securely in socket. Check gasket around perimeter of ignitor lid for proper seal. If gasket is missing or damaged, replace gasket. Room light can effect cad cell resistance. Reset safety switch.

• Close line switch to boiler. If burner starts

and runs beyond safety switch cut-off time, cell is good. If not, install new cell.

• Close hand valve in oil supply line.

• Failure occurs, device enters Recycle Mode.

• Device tries to restart system after

approximately 60 seconds.

• After third Recycle Mode trial, safety

switch locks out within safety switch timing indicated on label and control enters Restricted Mode. Ignition and motor stop and oil valves closes.

d. Power Failure Check: After Flame is

established, turn the power off to the control/ burner. The burner should shut down safely. When power is restored a normal ignition sequence should be started.

WARNING

Cad Cell Jumper must be removed after this check.

4. CHECK HIGH LIMIT

a. Adjust system thermostat(s) to highest setting.

b. Allow burner to run until boiler water

temperature exceeds high limit setting. The burner should shut down and circulators continue running.

c. Allow the temperature to drop below control

setting. The burner must restart.

d. Boiler installation is not considered complete

until this check has been made.

5. CHECK LOW WATER CUT-OFF CONTROL, if required on this boiler application. See Appendix "B" at the rear of this manual for 'How to Test'.

J. IF CONTROLS MEET REQUIREMENT outlined

in Paragraph I.

Allow boiler to operate for approximately 30 minute,

conrm the boiler and system have no leaks.

K. IF CONTROLS DO NOT MEET

REQUIREMENTS outlined in Paragraphs I-1 thru

I-5, replace control and repeat checkout procedures.

Page 47

XI: OPERATING

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:

• An external energy management system is installed that reduces the boiler water

temperature as the heating load decreases.

• This boiler is not used for any space heating.

• This boiler is part of a modular or multiple boiler system having a total input of

300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

Refer to the HydroStat 3250 Installation Instructions and Operating Manual included with these instructions.

Page 48

XII: MAINTENANCE AND SERVICE INSTRUCTIONS

A. WATER BOILERS:

1. Filling of boiler and system.

GENERAL — In a hot water heating system, the

boiler and entire system (other than the expansion tank) must be full of water for satisfactory operation. Water should be added to the system until the boiler pressure gauge registers 12 psi. To insure that the system is full, water should come out of all air vents when opened.

2. BOILING OUT OF BOILER AND SYSTEM. The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner:

a. Ideally, shut off valves have been installed

between the boiler return manifold and the rest of the system, to minimize the amount of system draining.

b. Drain the boiler to a level below the relief valve

tapping.

DANGER

Assure that the boiler is at zero pressure before removing the relief valve. Open the safety valve to relieve all internal pressure prior to proceeding. Safety valve discharge piping must be piped such that the potential for burns is eliminated.

c. Remove relief valve using extreme care to avoid

damaging it.

d. Add an appropriate amount of recommended boil

out compound.

e. Replace relief valve.

f. Fill the entire system with water.

g. Start ring the boiler.

h. Circulate the water through the entire system.

i. Vent the system, including the radiation.

j. Allow boiler water to reach operating

temperature, if possible.

k. Continue to circulate the water for a few hours.

l. Stop ring the boiler.

m. Drain the system in a manner and to a location

that hot water can be discharged with safety.

n. Remove plugs from all available returns and

wash the water side of the boiler as thoroughly as possible, using a high-pressure water stream.

o. Rell the system with fresh water.

3. Add appropriate boiler water treatment compounds

as recommended by your qualied water treatment

company.

4. Make pH or Alkalinity Test.

After boiler and system have been cleaned and relled

as previously described, test the pH of the water in the system. This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper,

except it gives specic readings. A color chart on the

side of the small hydrion dispenser gives the reading pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist. The pH should be higher than 7 but lower than 11. Add some of the washout chemical (caustic

soda), if necessary, to bring the pH within the specied

range. With this lower level of protection, care must be exercised to eliminate all of the free oxygen in the system.

5. Boiler is now ready to be put into service.

B. EXCESSIVE MAKE-UP WATER

A leaky system will increase the volume of make-up

water supplied to the boiler, which can signicantly

shorten the life of the boiler. Entrained in make-up water are dissolved minerals, salts and oxygen. When the fresh, cool make-up water is heated in the boiler, the minerals fall out as sediment, the salts coat the inside of the boiler, and the oxygen escapes as a gas. The accumulation of sediment eventually isolates the water from contacting the steel. When this happens the steel in that area gets extremely hot and eventually cracks. The presence of free oxygen or chloride salts in the boiler creates a corrosive atmosphere which, if the concentration becomes high enough, can corrode the steel through from the inside. More make-up water and higher concentrations of contaminants damage the boiler sooner.

Our warranty does not cover corrosion and sedimentrelated damage. Clearly it is in everyone’s best interest

to prevent this type of failure. You can do your part by ensuring that your system is leak-free, keeping leakage to less than 2 percent of the boiler water volume each month. Refer to chart below.

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD MORE WATER THAN INDICATED BELOW, CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS.

Model No.

FORCEOL084 0.20 2

FORCEOL115 0.20 2 FORCEOL147 0.25 3 FORCEOL189 0.30 4

Gallons Per

Month

Gallons Per

Year

Page 49

XII: Maintenance and Service Instructions (continued)

C. ATTENTION TO BOILER WHILE NOT IN

OPERATION

NOTICE

If boiler is not used during winter time, it must be fully drained to prevent freeze damage.

1. Prevent Freeze Damage Important: If boiler is NOT used during winter

time, it must be fully drained to prevent freeze damage.

2. Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners.

3. Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time.

4. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section X, System Start-Up, Paragraphs A through K.

WARNING

This boiler contains controls which may cause the boiler to shut down and not restart without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

Page 50

XIII: BOILER CLEANING

WARNING

All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner

swing door have a potential hazard which can cause severe property damage, personal injury or loss of life

if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental ring of burner

outside the combustion chamber. Disconnect the burner plug from the receptacle in the front jacket. Be sure to tighten swing door fastener completely when service is completed.

A. CLEAN THE FLUEWAYS (See Figure 40).

1. For access to the combustion chamber remove the

two (2) 3/8" - 16 cap screws. If boiler is equipped with exible fuel line(s), swing door open.

2. Remove the two smoke box clean-out covers from

the rear smoke box by removing the four 5/16"-18

hex head bolts. It is NOT necessary to remove the vent connector from the smoke box to clean boiler.

If necessary, remove the vent connector if there is

evidence of heavy soot accumulation in the boiler or to inspect base of chimney for condensate or accumulation of debris.

3. Remove the bafes (if installed) from the ue

passages. Refer to Section III, Paragraph F for

Bafe Installation.

4. Clean the 3rd Pass – Insert a 2" dia. x 42" long

wire or ber bristle brush into each of the two 3rd

passes. Using long strokes push the brush all the way through the boiler until the brush has exited the smoke box opening. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the

ue way until clean. Repeat the operation for the

other 3rd pass ue way.

5. Clean the 2nd Pass - Insert a 2" dia. x 42" long wire

or ber bristle brush into each of the two 2nd passes.

Using long strokes push the brush all the way through the boiler until the brush hits the back wall of the reversing chamber. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the

ue way until clean. Repeat the operation for the

other 2nd pass ue way.

6. Vacuum the loose debris in the bottom of the combustion chamber and smoke box.

C. AFTER CLEANING, vacuum all remaining debris

as necessary. Inspect burner swing door insulation, and rope gasket for signs of damage. If damaged, replace as needed.

D. REASSEMBLE BOILER.

CAUTION

Do not start the burner unless the burner swing door and canopy cover plates are secured in place.

1 Insert the bafes (if originally installed) into the

correct ue way. Refer to Section III, Paragraph F for Bafe Installation.

2. Attach the smoke box clean-out covers onto the rear of the boiler. Verify that the rope gasket is in good working order before assembly. Replace

rope gasket if necessary. Use the 3/8" hardware

originally removed. Do not over tighten. They should be snug but not bottomed out.

NOTICE

When securing burner swing door make sure door

is drawn-in equally on both sides.

Tighten swing door hardware to provide adequate

seal to rope gasket around perimeter of door.

Use an alternating tightening method from right side

to left side cap screw to pull door tight equally.

NOTICE

Do not overtighten. The rope gasket will provide

sufcient seal when the door is snugged into

place.

B. CLEAN THE COMBUSTION CHAMBER

Use a wire or ber bristle brush to clean the surfaces

of the combustion chamber. Vacuum all of the loose debris in the bottom of the combustion chamber.

Page 51

XIII: Boiler Cleaning (continued)

Figure 40: Cleaning of Boiler Flueways

WARNING

The boiler must be connected to an approved chimney in good condition. Serious property damage could

result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney ue must be

inspected and cleaned before the start of the heating season and should be inspected periodically throughout

the heating season for any obstructions. A clean and unobstructed chimney ue is necessary to allow noxious

fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler's

efciency.

Page 52

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. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

Page 53

XIV: TROUBLESHOOTING

A. COMBUSTION

1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the FORCEOL boiler is the result of extensive testing to obtain the best

ame shape and efcient combustion. Other brands

of the same spray angle and spray pattern may be used but may not perform at the expected level of CO2 and smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are massproduced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to have.

2. FUEL LEAKS — Any fuel leak between the pump and the nozzle will be detrimental to good combustion results. Look for wet surfaces in the air tube, under the ignitor, and around the air inlet. Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case

may become a re hazard.

3. SUCTION LINE LEAKS — Any such leaks should be repaired, as they may cause erratic burning of

the fuel and in extreme cases may become a re

hazard. Whatever it takes, The Oil Must Be Free of Air. This can be a tough problem, but it must be

resolved. Try bleeding the pump through a clear tube. There must be no froth visible. There are various test kits available to enable you to look at the oil through clear tubing adapted to the supply

line at the pump tting. Air eliminators are on the

market that have potential. Also, electronic sight glasses are being used with good success. At times,

new tubing must be run to the tank or new ttings

put on. Just make sure you get the air out before you leave.

Any air leaks in the fuel line will cause an unstable

ame and may cause delayed ignition noises. Use only are ttings in the fuel lines.

4. GASKET LEAKS — If 11.5 to 12.5% CO2 with a #1 smoke cannot be obtained in the breeching, look for air leaks around the burner mounting gasket, observation door, and canopy gasket. Such air leaks will cause a lower CO2 reading in the breeching. The

smaller the ring rate the greater effect an air leak

can have on CO2 readings.

5. DIRT — A fuel lter is a good investment.

Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle. The smaller the

ring rate, the smaller the slots become in the nozzle

and the more prone to plugging it becomes with the same amount of dirt.

6. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller amounts will cause excessive wear on the pump, but more importantly water doesn’t burn. It chills

the ame and causes smoke and unburned fuel to

pass out of the combustion chamber and clog the

ueways of the boiler.

7. COLD OIL — If the oil temperature approaching

the fuel pump is 40°F or lower, poor combustion or

delayed ignition may result. Cold oil is harder to atomize at the nozzle. Thus, the spray droplets get

larger and the ame shape gets longer. An outside

fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution is to locate the tank near the boiler in the basement utility room or bury the tank and lines

deep enough to keep the oil above 40°F. Check

environmental issues with local authorities having jurisdiction.

8. FLAME SHAPE — Looking into the combustion chamber through the observation port, the ame

should appear straight with no sparklers rolling up

toward the crown of the chamber. If the ame drags

to the right or left, sends sparklers upward or makes wet spots on the target wall, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described above.

9. START-UP NOISE — Late ignition is the cause

of start-up noises. If it occurs recheck for electrode

settings, ame shape, air or water in the fuel lines.

10. SHUT DOWN NOISE — If the ame runs out of

air before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-off valve in the fuel pump, or it may be air trapped in the

nozzle line. It may take several ring cycles for that

air to be fully vented through the nozzle. Water in the

fuel or poor ame shape can also cause shut down

noises.

NOTICE

CHECK TEST PROCEDURE. A very good test for isolating fuel side problems is to disconnect the

fuel system and with a 24" length of tubing, re out of an auxiliary ve gallon pail of clean, fresh,

warm #2 oil from another source. If the burner runs successfully when drawing out of the auxiliary pail then the problem is isolated to the fuel or fuel lines being used on the jobsite.

Page 54

XIV: Troubleshooting (continued)

B. OIL PRIMARY CONTROL 

1. Burner (Oil Primary) will not come on.

a. No power to Oil Primary.

b. Oil Primary is in lockout or restricted mode.

Press reset button for one (1) second to exit lockout. If control has recycled three times within the same call for heat, it will enter into restricted mode. To reset from restricted mode, refer to Section X, Paragraph I, Step 2 for details.

c. CAD cell seeing light.

d. CAD assembly defective.

e. Control motor relay is stuck closed (see note

below).

2. Burner (control) will light, then shut down after a short time, then restart after one (1) minute.

a. CAD cell is defective.

b. Air leaking into oil line causing ame out.

c. Defective nozzle causing ame to be erratic.

d. Excessive airow or draft causing ame to leave

burner head.

e. Excessive back pressure causing ame to be

erratic.

3. Control locks out after Trial For Ignition (TFI).

a. No oil to burner.

b. Shorted electrodes.

c. Nozzle clogged.

d. Airow too high.

e. Ignitor module defective.

f. CAD cell defective.

g. Oil valve stuck open or closed.

NOTE: The Safety Monitoring Circuit (SMC) is

designed to provide lockout in the event of a stuck or welded motor relay.

NOTICE

If ame is not established within 15 seconds of

oil valve actuation (known as Trial For Ignition [TFI]) lockout will occur. Lockout is indicated by a red LED solid-on located on the oil primary control.

Hard Lockout will occur if the Oil Primary Control locks-out three (3) times during a call for heat. This is indicated by red light reset button solid-on.

C. HYDROSTAT OIL BOILER CONTROL

Refer to the HydroStat 3250 Installation Instructions and Operating Manual included with these instructions.

Page 55

XV: REPAIR PARTS

All FORCE™ Repair Parts may be obtained by contacting your local Ferguson branch.

Page 56

1AA

Bare Boiler Assembly

XV: Repair Parts (continued)

Page 57

XV: Repair Parts (continued)

Item

Description Part No. FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189

No.

1. BARE BOILER ASSEMBLY

Cast Iron Section Assembly, 2 Section 103071-02 1 1 --- ---

Cast Iron Section Assembly, 3 Section 103071-03 --- --- 1 ---

Cast Iron Section Assembly, 4 Section 103071-04 --- --- --- 1

Spanner Bar Assembly w/Threaded Inserts, Painted, w/Hardware Installed (Includes Items 1C, 1D, 1E and 1F - Qty 1 ea.)

1-1/4" x 1-1/2" x 14-3/8" Lg. 100013-01 2 2 --- ---

1-1/4" x 1-1/2" x 20-3/8" Lg. 100013-02 --- --- 2 ---

1-1/4" x 1-1/2" x 26-3/8" Lg. 100013-03 --- --- --- 2

1C Carriage Bolt, 3/8"-16 x 1-1/4" Lg., Plated 100215-01 2 2 2 2

1D Cap Screw, 5/16"-18 x 7/8" Lg., Plated 80861371 2 2 2 2

1E Flat Washer, 5/16" USS, Plated 80860611 2 2 2 2

1F Hex Nut, 5/16-18, Serrated Flange, Plated 80860443 2 2 2 2

1G Hinge Bracket 100014-01 1 1 1 1

Hinge

5/16"-18 x 3/4" Lg. Cap Screw,

Plated

1J Cast Iron Burner Swing Door (Only) 102421-01 1 1 1 1

Burner Swing Door Insulation (Less

Pockets)

1L 1/2" Dia. Rope Gasket - Burner Swing Door 102022-01 1 1 1 1

1M 1/8" Dia. Rope Gasket - Observation Port 100096-01 1 1 1 1

1N Observation Port Cover 100015-01 1 1 1 1

5/16"-18 x 5/8" Lg. Socket Head Cap

Screw, Plated

1Q 3/8"-16 x 1-3/4" Lg. Tap Bolt, Plated 100102-01 2 2 2 2

1R 3/8" Flat Washer, USS, Plated 80860618 2 2 2 2

1S Smokebox 100021-01 1 1 1 1

1T 5/16" Flat Washer, USS, Plain 80860601 4 4 4 4

1U 5/16"-18 x 1" Lg. Cap Screw, Plain 80861307 4 4 4 4

1V 1/4" NPT Pipe Plug, Square Head, Brass 806603542 1 1 1 1

1W Smokebox Collar

1X 5/16" Flat Washer, USS, Plated 80860611 2 2 2 2

1Y 5/16"-18 x 7/8" Lg. Cap Screw, Plated 80861371 6 6 6 6

1Z Cast Iron Clean-Out Cover (only) 100104-01 2 2 2 2

1AA 1/2" Dia. Rope Gasket - Clean-Out Cover 100095-01 2 2 2 2

Bracket

Mount Burner

5" Dia. 6" Dia.

80861340

100039-01 1 1 1 1

100050-01 1 1 1 1

100092-01 1 1 --- ---

100093-01 --- --- 1 1

2 2 2 2

3 3 3 3

Page 58

Jacket Assembly

XV: Repair Parts (continued)

Page 59

XV: Repair Parts (continued)

Item

Description Part No.

No.

2. JACKET ASSEMBLY

Complete Jacket Kit 106443-02 1 1 --- ---

Complete Jacket Kit 106443-03 --- --- 1 ---

Complete Jacket Kit 106443-04 --- --- --- 1

FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189

Page 60

XV: Repair Parts (continued)

Water Boilers - Trim and Controls

Page 61

XV: Repair Parts (continued)

Item

Description Part No.

No.

FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189

3. WATER BOILERS - TRIM AND CONTROLS

Beckett AFG Oil Burner w/Gasket:

FORCEOL084 Spec No. NY2802 102415-01 1 --- --- ---

FORCEOL115 Spec No. NY2803 102415-02 --- 1 --- ---

FORCEOL147 Spec No. NY2804 102415-03 --- --- 1 ---

FORCEOL189 Spec No. NY2805 102415-04 --- --- --- 1

Beckett NX Oil Burner w/Gasket

FORCEOL147 Spec No. NY2903 106109-03 --- --- 1 ---

FORCEOL189 Spec No. NY2904 103369-01 --- --- --- 1

(Note: See Page 62 for Beckett AFG Burner Parts Breakdown or Page 64 for Beckett NX Burner Parts Breakdown)

3B Oil Primary Control, Beckett GeniSys 7505B 103447-01 1 1 1 1

3C Stainless Steel 2

3D Stainless Steel 3

Temperature & Pressure Gauge, 2-1/2" Dia., 1-1/2" Shank,

1-1/4 NPT, 70-320, 0-75#

Honeywell #123872A Immersion Well,

1/2" NPT, 3" Insulation

Limit Rated Temperature Sensor Only, 12" Length 103195-01 1 1 1 1

HydroStat 3250 Plus/Burner Harness Assembly (Does Not

Include Sensor

(Control Only, HydroStat 3250 Plus) 105287-01 1 1 1 1

Relief Valve, 3/4" NPT M x F, Conbraco #10-407-05

Relief Valve, 3/4" NPT F x F, Watts #374A-050

3J Nipple, 1-1/4" NPT x 5" Lg. 100090-01 1 1 1 1

3K Nipple, 1-1/2" NPT x 6" Lg. 806600203 1 1 1 1

3L Tee, 1-1/4" x 1-1/4" x 3/4" NPT 806601032 1 1 1 1

3M Tee, 1-1/2" x 1-1/2" x 3/4" NPT 806601105 1 1 1 1

3N Street Elbow, 3/4" 806601501 1 1 1 1

3P Drain Valve, 3/4" NPT, Conbraco #35-302-03 806603061 1 1 1 1

3Q Pipe Plug, 1-1/4" NPT 806603502 1 1 1 1

3R Return Injector 102758-01 1 1 1 1

3S Elbow, 2" NPT x 1-1/2" NPT 806601581 1 1 1 1

3T Self Drilling TEK Screw, #10 x 1/2", Hex Washer Head 80860711 3 3 3 3

* 3/4" NPT close pipe nipple must be eld supplied for installation of this valve

Pass Flue Bafe

Pass Flue Bafe 100081-01 2 2 --- ---

30 PSI

40 PSI

50 PSI

100042-01 --- --- 2 2

102066-01 --- 2 --- ---

100282-01 1 1 1 1

80160497 1 1 1 1

105258-01 1 1 1 1

81660363

81660370*

103837-01*

1 1 1 1Relief Valve, 3/4" NPT F x F, Conbraco #10-303-07

Page 62

Beckett AFG Burner

XV: Repair Parts (continued)

Page 63

XV: Repair Parts (continued)

BECKETT AFG OIL BURNER PART NOS. FOR FORCEOL SERIES BOILERS

NATURAL DRAFT APPLICATIONS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.

Boiler Model

FORCEOL084 FORCEOL115 FORCEOL147 FORCEOL189

Air Tube Combination AFG70MQASN AFG70MPASN AFG70MMAQN AFG70MLASN

Beckett's Spec. No. NY2802 NY2803 NY2804 NY2805

Air Band 31840 31840 3492 3492

Air Band Nut 4150 4150 4150 4150

Air Band Screw 4198 4198 4198 4198

Air Shutter 3709 3709 3709 3709

Air Shutter Screw 4198 4198 4198 4198

Blower Wheel 2999 2999 2999 2999

Coupling 2454 2454 2454 2454

Low Firing Rate Bafe 3708 --- --- ---

Bulkhead Knurled Locknut 3666 3666 3666 3666

Connector Tube Assembly 5636 5636 5636 5636

Electrode Clamp 149 149 149 149

Electrode Clamp Screw 4219 4219 4219 4219

Electrode Insulator Assembly 5780 5780 5780 5780

Spider Spacer Assembly 5503 5503 5503 5503

Escutcheon Plate 3493 3493 3493 5941

Adjusting Plate Assembly --- --- --- 5941

Head 51895 51895 5912 5913G

Head Screws 4221 4221 4221 4221

Flange Gasket 32388 32388 32388 32388

AFG Housing 5874 5874 5874 5874

Motor 21805 21805 21805 21805

Nozzle Adapter 213 213 213 213

Nozzle Line Electrode Assembly NL70MB NL70MB NL70MM NL70MD

Oil Pump, Clean Cut (Single Stage) 2184404U 2184404U 2184404U 2184404U

Oil Pump, Clean Cut (Two-Stage) 51975U 51975U 51975U 51975U

Static Plate 3384 3383 3384 ---

Ignitor 51771U 51771U 51771U 51771U

Ignitor Hinge Screw 4217 4217 4217 4217

Ignitor Holding Screw 4292 4292 4292 4292

Ignitor Gasket Kit 51304 51304 51304 51304

Wire Guard 10251 10251 10251 10251

Junction Box 5770 5770 5770 5770

Flame Detector 7006 7006 7006 7006

Oil Solenoid Valve Coil 21775U 21775U 21775U 21775U

Oil Solenoid Valve Cord 21807 21807 21807 21807

Page 64

Beckett NX Burner

XV: Repair Parts (continued)

Page 65

XV: Repair Parts (continued)

BECKETT NX OIL BURNER PART NOS. FOR FORCEOL SERIES BOILERS

DIRECT VENT APPLICATIONS

NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.

Item

No.

11a Gasket, Igniter Baseplate

11b Gasket, Igniter Baseplate Hinge

11d Gasket, Rear Access Door

Shown

Part Description

Complete Oil Burner (without Primary Control) NY2905 BCB7904

1 Air Adjustment Mechanism Assembly 51794U

2 Air Guide 101101U

3 Heat Shield (where used/optional) Specify

Air Tube Combination NX70LB NX90LD

Air Tube Mounting Screws #8 x 3/8" 4396

5 Blower Wheel 29994U

6 Connector Tube Assembly, 11" 51127

7 Coupling 2454

8 Rear Access Door 32119U

9 Electrodes Insulator Kit 51811U

Fuel Unit, Single Stage, A2EA6520N621L 2184404U

Fuel Unit, Two Stage 51975U

Mounting Screws 1/4 -20 x 7/8" 4189

11c Gasket, Wiring

15 Igniter, Electronic 51771U

16 Inlet Air Box 1010U

18 Inlet Air Adapter, Outside Air Kit 1014U

19 Nozzle Line Electrode and Head Assembly Specify

Motor 21805U

Mounting Screws 1/4 -20 x 7/8" 4189

21 Primary Safety Control Specify

22 Retention Head Assembly - 6 Slot 51785U

23 Retention Head Assembly - 9 Slot 51815U

24 Splined Nut 3666

25 Spring, Igniter Prop 32058PU

26 Wiring Box 5770

27 Low Firing Rate Bafe (If applicable) 32229U

28 Cover, Burner 51812U

29 Mounting Plate, Burner Cover 32103U

30 Thumbscrews, Cover Mounting 21899U

Gasket, Flange 32087

Not

Main Housing Assembly 51783

Nozzle Line Heater (If applicable) 51621

FORCEOL147 FORCEOL189

Beckett Part Numbers

51942U

Page 66

XV: Repair Parts (continued)

Item No. Description Part No. FORCEOL147 FORCEOL189

4. DIRECT VENT KITS AND PARTS

4A Direct Vent Conversion Kit 106401-01 1 1

Adapter, Appliance, FDVS, 5-6 100234-02 1 1

Clamp, 6" Appliance, FDVS-6, Half 100235-02 2 2

Not Shown

6. FLEX OIL VENT PIPE FOR DIRECT VENT

Not Shown

7. BECKETT NX BURNERS FOR DIRECT VENT

Assy., Cover Sleeve, FDVS-5 100236-02 2 2

Assy., Cover Ring, FDVS-5 100237-02 2 2

Clamp, Inner Pipe FDVS-5, Half 100238-02 4 4

5" Dia. x 5 ft. FOVP-505 100211-02

5" Dia. x 10 ft. FOVP-510 100212-02

5" Dia. x 15 ft. FOVP-515 100213-02

5" Dia. x 20 ft. FOVP-520 100214-02

1 1

Not Shown

FORCEOL147 106109-03 1 ---

FORCEOL189 103369-01 --- 1

Page 67

Approx.

Overre

Approx.

Overre

Breech

Approx.

Pressure

Bafes OUT

Bafes IN

(3)

(" w.c.)

(3)

(" w.c.)

(3)

(" w.c.)

. Actual eld conditions may be

Breech

Minimum

Bafes OUT

Bafes IN

Pressure

Breech

Pressure

Minimum

(3)

(" w.c.)

(3)

(" w.c.)

(3)

Approx.

Increase

Stack Temp.

Bafe

Approx.

Insertion

Head

Pump

Air Band

(2)

°F

Bafes

Without

(pass)

Location

(%)

Shipped

(Inch)

Depth

Type

(setting)

(PSI)

Pressure

(setting)

0 150 L2 2 11.5 --- --- 0 --- +0.005

84 0 +0.040 +0.020

and 3

65 0 +0.040 +0.020

Overre

Pressure

Minimum

Bafes OUT

Minimum

Bafes IN

Approx.

Stack Temp.

Bafe

Approx.

Pump

(" w.c.)

(3)

Overre

Pressure

(" w.c.)

(2)

Without

Increase

Bafes °F

(pass)

Location

(%)

Shipped

(PSI)

Pressure

75 +0.06 +0.045 +0.045 +0.03

180

70 +0.10 +0.05 +0.08 +0.04

---

11.5

150

(1)

6 0 150 L2 2 11.5 2

7 1 150 L1 2 11.5 3

7 2 150 V1 (0) 2 11.5 --- --- 0 --- +0.030

Delavan

0.85 x 60B

1.10 X 60B

FORCEOL147 1.05 AFG

FORCEOL189 1.35 AFG

Nozzle

Hago

(setting)

Head / Air

Adjustment

Input

(GPH)

Burner

FORCEOL084 at 0.60 GPH ring rate utilizes a low re bafe.

The increased stack temperature with the bafes removed is an approximation, based on a constant supply temperature of 180°F and 11.5% CO

(1)

Notes

(2)

These values are minimum and could be as much as -.03" w.c., more without impacting performance. Pressures based on 11.5% CO

4) Single stage fuel pump is standard, two-stage fuel pump is optional. Burner manufacturer has preset single stage fuel pump to settings shown in table above. Two-stage fuel pump

is factory set at 140 PSI and must be readjusted to settings shown above during burner start-up.

(3)

different.

TABLE 10: BECKETT NX BURNER SPECIFICATIONS - DIRECT VENT

Boiler Model

Hago

Delavan

1.00 x 45°B

.0.75 x 60°W

FORCEOL189 1.35 1.00

FORCEOL147 1.05 2.75

The increased stack temperature with the bafes removed is an approximation, based on a constant supply temperature of 180°F and 11.5% CO

Notes

(2)

These values are representative for max vent and air intake piping conditions @ 180°F supply water temperature and 11.5% CO

(3)

Actual eld values may be different.

4) Single stage fuel pump is standard, two-stage fuel pump is optional. Burner manufacturer has preset single stage fuel pump to settings shown in table above.

Two-stage fuel pump is factory set at 140 PSI and must be readjusted to settings shown above during burner start-up.

TABLE 9: BECKETT AFG BURNER SPECIFICATIONS - CHIMNEY VENT

(setting)

Air Shutter

Nozzle

Model

Burner

Input

(GPH)

Burner

Boiler Model

Delavan

0.65 x 45B

0.50 x 45W

FORCEOL115 0.82 AFG

FORCEOL084 0.60 AFG

APPENDIX A: BURNER SPECIFICATIONS

Page 68



WARNING

DO NOT ATTEMPT to cut factory wires to install an aftermarket Low Water Cut Off (LWCO).

Only use connections specically identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off (LWCO) manufacturer's instructions.

When

A low water cutoff is required to protect a hot water

boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e.

baseboard on the same oor level as the boiler). In

addition, some jurisdictions require the use of a LWCO with a hot water boiler.

Where

The universal location for a LWCO on both gas and oil

hot water boilers is above the boiler, in either the supply or return piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely.

It is recommended that the LWCO control is installed

above the boiler to provide the highest level of protection. However, where the LWCO control is approved by the LWCO control manufacturer for installation in a high boiler tapping of a water boiler, the use of the listed LWCO control is permitted when it is installed according to the LWCO manufacturer’s instructions.

What Kind

Typically, in residential applications, a probe type

LWCO is used instead of a oat type, due to their

relative costs and the simplicity of piping for a probe LWCO.

connection must have a prevent bridging between the probe and the tee. Also, the run of the tee must have a minimum diameter to prevent the end of the probe from touching or being located too close to the inside wall of the run of the tee.

Ideally, manual shutoff valves should be located

above the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe.

minimum diameter to

How to Wire

LWCO’s are available in either 120 VAC or 24 VAC

congurations. The 120 VAC conguration can be

universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped).

The presence of water in a properly installed LWCO

will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.

It is recommended to supply power to the probe LWCO

with the same line voltage boiler service as shown below.

How to Pipe

A “tee” is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch

LWCO Location

Wiring of Typical LWCO

Page 69

Appendix B: Low Water Cut-off (LWCO) on Hot Water Boilers (continued)

A 24 VAC LWCO is used primarily for gas red

boilers where a 24 volt control circuit exists within the boiler. However, a 24 VAC LWCO can only be used if the boiler manufacturer has provided piping and wiring connections and instructions to allow for this application.

How to Test

Shut off fuel supply. Lower water level until water level is BELOW the LWCO. Generate a boiler demand by turning up thermostat. Boiler should not attempt to

operate. Increase the water level by lling the system.

The boiler should attempt to operate once the water level is above the LWCO.

Page 70

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Page 72

PROSELECT FORCEOL084, FORCEOL115, FORCEOL147, FORCEOL189 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual