PROSELECT FORCEOL084, FORCEOL115, FORCEOL147, FORCEOL189 Installation Manual
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
efciency 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
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
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.
2
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.
3
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
4
Appendix A
Burner Specications........................................
Appendix B
Low Water Cut Off............................................
67
68
RELIEF
VALVE
SMOKEBOX
PRESURE
"
3
CLEAN
TAPPING
OUT COVER
8
21
DRAIN VALVE
"NPT SYSTEM
1
2
1
COLLAR
SMOKEBOX COLLAR
SPANNER BAR W/
ADJUSTABLE LEGS
"
1
4
13
Figure 1: FORCEOL084 through FORCEOL189
"
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)
I: GENERAL INFORMATION
4
3
20 "
"
11
16
3
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:
5
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)
6
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
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"
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
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.
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"
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
9
III: Packaged Boiler Assembly - Trim & Controls (continued)
10
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.
III: Packaged Boiler Assembly - Trim & Controls (continued)
Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)
11
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.
12
Figure 4C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed
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
13
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.
14
Figure 8: Piping Arrangement for Drain Valve and Indirect Water Heating Return
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
2
P/N 102066-01
P/N 100042-01
Bafe Usage
nd
Pass 3rd Pass
[2]
[2]
[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 bafes. Bafe
requirements differ from model to model, see
Table 3.
NOTE: Read caution statement before proceeding.
CAUTION
These bafes will generate higher efciencies
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 bafes until you have read
Sections VI and VII, completely (venting details).
Install stainless steel bafes provided in
miscellaneous parts carton as follows, refer to Table
3 and Figure 9:
• Model FORCEOL084 - To install ueway
bafe in 3rd pass on left side of boiler, hold
bafe with word "Left" readable at the top.
Slide bafe in ueway until position tab
touches ns on left side of 3rd pass ueway.
To install ueway bafe in 3rd pass ueway
on right side of boiler, hold bafe with word
"Right" readable at the top. Slide bafe in
ueway until position tab touches ns on
right side of 3rd pass ueway.
• Model FORCEOL115 - To install ueway
bafe in 3rd pass on left side of boiler, hold
bafe with word “Left” readable at the top.
Slide bafe in ueway until position tab
touches ns on left side of 3rd pass ueway.
To install ueway bafe in 3rd pass ueway
on right side of boiler, hold bafe with word
“Right” readable at the top. Slide bafe
in ueway until position tab touches ns
on right side of 3rd pass ueway. To install
ueway bafe in 2nd pass on left side of
boiler, hold bafe with word “Left” readable
at the top. Slide bafe in ueway until
position tab touches ns on left side of 3rd
pass ueway. To install ueway bafe in
2nd pass ueway on right side of boiler, hold
bafe with word “Right” readable at the top.
Slide bafe in ueway until position tab
touches ns on right side of 3rd pass ueway.
• Models FORCEOL147 and FORCEOL189
To install ueway bafe in 2nd pass ueway
on left side of boiler, hold bafe with word
"Left" readable at the top. Slide bafe in
ueway until position tab touches ns on
right side of 2nd pass ueway. To install
ueway bafe in 2nd pass ueway on right
side of boiler, hold bafe with word "Right"
readable at the top. Slide bafe in ueway
until position tab touches ns on left side of
2nd pass ueway.
NOTE: 2nd and 3rd pass ueway bafe 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.
15
III: Packaged Boiler Assembly - Trim & Controls (continued)
16
Figure 9: Bafe Orientation in Flueways
IV: WATER BOILER PIPING
NOTICE
Failure to pipe boiler as specied 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.
17
IV: Water Boiler Piping (continued)
18
Figure 10A: Recommended Water Piping for Circulator Zoned Heating Systems - Supply Side Circulator
IV: Water Boiler Piping (continued)
Figure 10B: Recommended Water Piping for Zone Valve Zoned Heating Systems - Supply Side Circulator
19
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.
20
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
21
A. CHIMNEY VENTING
1. Chimney venting is an important part of a safe
and efcient oil red appliance system. Contact
your local re and building ofcials on specic
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. sufcient 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
qualied 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 sufcient 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 qualied 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 qualied 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
22
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 specied
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.
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