PROSELECT FORCEOL84-E, FORCEOL115-E, FORCEOL140-E, FORCEOL182-E Installation Manual
Installation, Operating and Service Instructions for
• High Efficiency
• Oil-Fired, 3-Pass
FORCE™ OIL
Residential
Models:
• FORCEOL84-E
• FORCEOL115-E
• FORCEOL140-E
• FORCEOL182-E
Manual Contents Page
General Information ......................5
Pre-installation ..........................7
Packaged Boiler Assy. - Trim & Controls .....9
Water Boiler Piping .....................17
Indirect Water Heater Piping ..............21
Natural Draft Venting (Chimney) ...........22
Direct Venting/Air Intake Piping ...........26
Electrical ..............................33
Oil Piping .............................37
System Start-up ........................39
Operating .............................46
Service and Maintenance ................48
Boiler Cleaning ........................50
Troubleshooting ........................53
Service Parts ..........................55
Burner Specifications ...................66
Appendix A Aftermarket LWCO ...........66
• Water Boiler
• Natural Draft or Direct Vent
(140-E and 182-E)
As an ENERGY STAR® Partner, U.S. Boiler Company
has determined that the FORCEOL meet the
ENERGY STAR® guidelines for energy efficiency
established by the United States Environmental
Protection Agency (EPA).
TO THE INSTALLER:
Affix these instructions adjacent to boiler.
TO THE CONSUMER:
Retain these instructions for future reference.
106346-06 - 8/19
9700609
FORCE
Installation, Operating & Service Manual
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, Fire
places, 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 a hazardous situation that, if not
avoided, will result in death or serious injury.
!
WARNING
Indicates a hazardous situation that, if not
avoided, could result in death or serious injury.
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.
Indicates a hazardous situation that, if not
avoided, could result in minor or moderate
injury.
NOTICE: Indicates special instructions on
installation, operation, or service which are
important but not related to personal injury
hazards.
CAUTION
2
106346-06 - 8/19
FORCE
!
DANGER
DO NOT store or use gasoline or other flammable 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 supply
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 flooring. DO NOT install boiler on carpeting.
• DO NOT tamper with or alter the boiler or controls.
• Inspect flueways at least once a year - preferably at the start of the heating season. The inside of the
combustion chamber, the vent system and boiler flueways should be cleaned if soot or scale has
accumulated.
Installation, Operating & Service Manual
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.
106346-06 - 8/19
3
FORCE
WARNING
!
• This boiler contains very hot water under high pressure. DO NOT unscrew any pipe fittings 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 flue 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 flue, connector or smokepipe joints may be signs of condensing flue 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 flammable debris, rags, paper,
wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of fire
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 firing of burner outside the combustion chamber. Be sure to tighten swing door
fasteners completely when service is completed.
Installation, Operating & Service Manual
4
106346-06 - 8/19
NOTES:
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.
1 General Information
RELIEF
VALVE
SMOKEBOX
FORCE
TAPPING
PRESURE
Installation, Operating & Service Manual
"
3
CLEAN
OUT COVER
8
21
DRAIN VALVE
"NPT SYSTEM
1
2
1
COLLAR
SMOKEBOX COLLAR
SPANNER BAR W/
ADJUSTABLE LEGS
"
1
4
13
Figure 1: FORCE OIL Dimensions
"
8
7
31
CONNECTION
"NPT SYSTEM RETURN
1
2
1
12" MIN
CLEARANCE
(SEE NOTE 1)
REAR SERVICE
4
3
5 "
BOILER
CONTROL
SUPPLY
CONNECTION
GAUGE
TEMP/PRESSURE
FRONT SERVICE
DIA.
CLEARANCE
(FLUEWAY CLEANING)
"
11
16
3
106346-06 - 8/19
4
3
20 "
WELL
IMMERSION
PORT
DOOR
FLAME
BURNER
SWING
OBSERVATION
BURNER
BECKETT AFG
(SHOWN)
19" MIN.
(SEE NOTE 3)
(FULLY OPEN)
BURNER SWING
DOOR CLEARANCE
5
1 General Information (continued)
Table 1A: Dimensional Data (See Figure 1)
FORCE
Installation, Operating & Service Manual
Dimensions See Figure 1
Boiler Model
FORCEOL084-
E/115-E
FORCEOL140-E 23” 24” 6” 11.08 20.29 567
FORCEOL182E 29” 30” 6” 14.46 27.29 660
NOTE: 1. Maximum Working Pressure: Water: 30 PSI Shipped From Factory (Standard),
50 PSI Optional
Table 1B: Rating Data
Boiler Model
FORCEOL084-E 0.60 84 6 8 x 8 15 N/A N/A
FORCEOL115-E 0.80 115 6 8 x 8 15 N/A N/A
FORCEOL140-E 1.00 140 6 8 x 8 15 106401-01 5
FORCEOL182-E 1.30 182 7 8 X 8 15 106401-01 5
“A” “B” “C”
17” 24” 5” 7.70 13.29 475
Burner Capacity
GPH MBH
In. Dia.
Minimum Chimney
Recommendations
Round
Water Content -
Rectangle
In. x In.
Gallons
Height
Ft.
Heat Transfer
Surface Area -
Sq. Ft.
Direct Vent System
Kit
Part Number
Actual Shipping
Vent Connector
Dia. Inch
Weight (LB.)
6
106346-06 - 8/19
2 Pre-Installation
FORCE
Installation, Operating & Service Manual
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 filed 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 final 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 floor is
not level, or if water may be encountered on floor
around boiler.
4. PROVIDE RECOMMENDED SERVICE
CLEARANCE, if applicable, as follows:
a. Clearance from Jacket Front Panel -
• 24" for servicing burner
• 24" for flueway cleaning (FORCEOL084-E
through FORCEOL140-E).
• 30" for flueway cleaning (FORCEOL182-E)
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. FORCE OIL boilers can be installed in rooms with
clearances from combustible material as listed above.
Listed clearances cannot be reduced for alcove or
closet installations.
106346-06 - 8/19
18"
18"
6"
3. For reduced clearances to combustible material,
protection must be provided as described in the above
ANSI/NFPA 31 standard.
18"
18"
7
2 Pre-Installation (continued)
FORCE
Installation, Operating & Service Manual
5. For minimum clearances to combustible
materials. See Figures 2A and 2B.
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.
D. DIRECT VENT CONFIGURATIONS requires:
1. Beckett NX Burner
2. Direct Vent conversion Kit
3. Double Wall Flex Oil Vent Pipe (FOVP)
Table 2: Direct Vent Configuration Components
Boiler
Model
Beckett NX
Oil Burner
Part No.
FORCEOL140-E 106109-03
FORCEOL182-E 103369-01
Direct Vent
Conversion Kit
Part No.
106401-01
WARNING
!
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
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, fabric softeners,
etc.) are used or stored.
FOVP Carton Part No.
100212-02 - 10 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. FORCE OIL boilers can be installed in rooms with
clearances from combustible material as listed above.
Listed clearances cannot be reduced for alcove or closet
installations.
8
FDVS
AIR
INTAKE
PIPING
DIRECT
VENT
VENT
PIPING
6"
3. For reduced clearances to combustible material,
protection must be provided as described in the above
ANSI/NFPA 31 standard.
3"
3"
3"
6"
106346-06 - 8/19
FORCE
Installation, Operating & Service Manual
3 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 floor. 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 floor.
Step 8. If wood block was placed under front
legs, lift pipe handles, remove wooden
block and lower front legs to floor. Remove
pipe handles.
CAUTION
!
Do not drop boiler. Do not bump boiler jacket
against floor.
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 field service.
1. TO OPEN BURNER SWING DOOR
(see Figures 4A and 4B).
106346-06 - 8/19
Figure 3: Packaged Boiler Removal from Skid
9
FORCE
Installation, Operating & Service Manual
3 Packaged Boiler Assembly - Trim & Controls (continued)
Figure 4A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured
Step 1. Loosen but do not remove left side
latching hardware (3/8" x 1-3/4" lg. tap bolt).
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 power from boiler.
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.
10
106346-06 - 8/19
FORCE
Installation, Operating & Service Manual
3 Packaged Boiler Assembly - Trim & Controls (continued)
Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)
106346-06 - 8/19
11
FORCE
Installation, Operating & Service Manual
3 Packaged Boiler Assembly - Trim & Controls (continued)
2. Perform routine inspection, service or cleaning
as necessary.
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 (3/8"-16 x
1-3/4" lg. tap bolt and flat washer) first,
then install left side hinge hardware (3/8"16 x 1-3/4" lg. tap bolt and flat washer)
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 screw first. 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 flange bolt first 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 fiberglass 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.
12
Figure 4C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed
106346-06 - 8/19
FORCE
Installation, Operating & Service Manual
3 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 2
make an impression in door insulation to seal
the chambers.
If insulation is damaged, 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.
nd
and 3rd pass flueway should
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 floor 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. Secure HydroStat 3250 Plus
control to the hinge side Side Panel with
supplied sheet metal screws as shown
in Figure 5.
106346-06 - 8/19
Figure 5: Supply Piping and HydroStat 3250 Plus Control Assembly Details
13
FORCE
Installation, Operating & Service Manual
3 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 Electro-well located in the
front section until it rests against the
bottom of the well. Secure sensor to
Electro-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 sheetmetal 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 fittings 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.
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.
14
Figure 8: Piping Arrangement for Drain Valve and Indirect Water Heating Return
106346-06 - 8/19
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Installation, Operating & Service Manual
3 Packaged Boiler Assembly - Trim & Controls (continued)
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 floor drain,
when tightening these fittings,
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
Baffle Usage
Boiler Model
FORCEOL084-E
FORCEOL115-E
FORCEOL140-E
FORCEOL182-E
nd
2
Pass 3rd Pass
[2]
P/N 102066-01
[2]
P/N 109902-01
[2]
P/N 100042-01
None None
[2]
P/N 100081-01
None None
Combustion
Chamber
P/N 109901-01
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 field wiring from the circulator to
the HydroStat 3250 control. Make the wiring
connections as shown on Figures 27 and 28.
6. Installing stainless steel flueway baffles. Baffle
requirements differ from model to model, see
Table 3.
NOTE: Read caution statement before
proceeding.
CAUTION
!
These baffles will generate higher efficiencies
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 baffles until you have read
Sections VI and VII, completely (venting
details).
[1]
Install stainless steel baffles provided in
miscellaneous parts carton as follows, refer to
Table 3 and Figure 9:
•
FORCEOL084E - To install flueway baffle
in 2nd pass on left side of boiler, hold
baffle with word "Left" readable at the
top. Slide baffle in flueway until position
tab touches fins on left side of 2nd pass
flueway. To install flueway baffle in 2nd
pass flueway on right side of boiler, hold
baffle with word "Right" readable at the
top. Slide baffle in flueway until position
tab touches fins on right side of 2nd
pass flueway.
• Model EMP115E - To install flueway
baffle in 3
rd
pass on left side of boiler,
hold baffle with the word "Left" readable
at the top. Slide baffle in flueway until
position tab touches fins on left side
of 3rd pass flueway. To install flueway
baffle in 3rd pass flueway on right side
of boiler, hold baffle with word "Right"
readable at the top. Slide baffle in
flueway until position tab touches fin on
right side of 3
rd
pass flueway. To install
flueway baffle in 2nd pass on left side
of boiler, hold baffle with word "Left"
readable from the top. Slide baffle in
flueway until position tb touches fins on
left side of 3rd pass flueway. To install
flueway baffle in 2nd pass flueway on
right side of boiler, hold baffle with word
"Right" readable at the top. Slide baffle
in flueway until position tab touches fins
on right side of 3rd pass flueway.
To install combustion chamber Ring,
set ring in the front section of the
combustion chamber.
• FORCEOL140-E and FORCEOL182-E To
install flueway baffle in 2nd pass flueway
on left side of boiler, hold baffle with
word "Left" readable at the top. Slide
baffle in flueway until position tab
touches fins on right side of 2nd pass
flueway. To install flueway baffle in 2nd
pass flueway on right side of boiler, hold
baffle with word "Right" readable at the
top. Slide baffle in flueway until position
tab touches fins on left side of 2nd pass
flueway.
NOTE: 2nd and 3rd pass flueway baffle are not
interchangeable.
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15
FORCE
Installation, Operating & Service Manual
3 Packaged Boiler Assembly - Trim & Controls (continued)
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.
16
Figure 9: Baffle Orientation in Flueways
106346-06 - 8/19
FORCE
Installation, Operating & Service Manual
4 Water Boiler Piping
NOTICE: Failure to pipe boiler as specified 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 fittings.
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 fittings 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 flow rate to minimize areas of
overheating
a. Design system to ensure that the flow 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 Flow Rate (Gal / Min)
FORCEOL084-E 4.5
FORCEOL115-E 4.5
FORCEOL140-E 8.0
FORCEOL182-E 10.0
WARNING
!
Do not operate boiler below minimum volumetric
flow 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 flow 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 HydroAir Systems. Refer to the Indirect Water Heater
Installation, Operating, and Service Instructions
for additional information.
4. The FORCE OIL 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 flue 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 flow for maintenance of higher
boiler water temperature.
106346-06 - 8/19
17
4 Water Boiler Piping (continued)
FORCE
Installation, Operating & Service Manual
18
Figure 10A: Recommended Water Piping for Circulator Zoned Heating Systems - Supply Side Circulator
106346-06 - 8/19
4 Water Boiler Piping (continued)
FORCE
Installation, Operating & Service Manual
106346-06 - 8/19
Figure 10B: Recommended Water Piping for Zone Valve Zoned Heating Systems - Supply Side Circulator
19
4 Water Boiler Piping (continued)
FORCE
Installation, Operating & Service Manual
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 first 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 first 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.
20
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5 Indirect Water Heater Piping
FORCE
Installation, Operating & Service Manual
A. CONNECT INDIRECT DOMESTIC WATER
HEATER PIPING as shown in Figures 12A and
12B.
Also refer to Figures 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
106346-06 - 8/19
21
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