PROSELECT FORCEVFO-3-075E, FORCEVFO-3-100E, FORCEVFO-4-120E, FORCEVFO-4-150E, FORCEVFO-5-175E Installation Manual

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Page 1

Installation, Operating and Service Instructions for

FORCEVFO Residential Water

Models:

• FORCEVFO-3-075E

• FORCEVFO-3-100E

• FORCEVFO-4-120E

• FORCEVFO-4-150E

• FORCEVFO-5-175E

• FORCEVFO-5-190E

Manual Contents Page

1. Dimensional Description, Specification &

Dimensional Data .....................4

2. Pre-installation .......................8

3. Packaged Boiler Assembly ............10

4. Water Boiler Piping & Trim .............11

5. Tankless & Indirect Water Heater Piping ..15

6. Venting ............................17

7. Electrical ...........................20

8. Oil Piping ...........................23

9. System Start-Up .....................25

10. Operating ..........................28

11. Maintenance & Service ...............34

12. Boiler Cleaning .....................36

13. Troubleshooting .....................38

14. Service Parts .......................40

15. Burner Specifications ................46

Appendix ..........................47

• FORCEVFOT-3-075E

• FORCEVFOT-3-100E

• FORCEVFOT-4-120E

• FORCEVFOT-4-150E

• FORCEVFOT-5-175E

• FORCEVFOT-5-190E

• Water Boiler

• Natural Draft

• Oil-Fired

TO THE INSTALLER:

Affix these instructions adjacent to boiler.

9700609

TO THE CONSUMER:

Retain these instructions for future reference.

As an ENERGY STAR Partner, U.S. Boiler Company has determined that the FORCEVFO-3-075E, FORCEVFOT-3-075E, FORCEVFO-4-120E, and FORCEVFOT-4-120E meets the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).”

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.

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FORCEVFO Installation & 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, a copy of which is included with this boiler. 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

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FORCEVFO Installation & Service Manual

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 boiler before installing, starting-up, operating, maintaining or servicing this boiler. Keep this manual and literature in legible condition and posted near boiler 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 tapping located on top left corner of front section- See Piping and Trim 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 installation is complete including verifying that the limit sensor is fully installed (seated in bottom of Well).

• 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.

• When cleaning this boiler, DO NOT damage combustion chamber liner and/or rear target wall. If damaged, combustion chamber 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 boiler with jumpered or absent controls or safety devices.

• Do not operate boiler 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 boiler.

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FORCEVFO Installation & Service Manual

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.

• High water temperatures increase the risk of scalding injury. If this boiler is equipped with a tankless heater for domestic water supply, a flow regulator and automatic mixing valve must be installed properly in tankless heater piping. See Piping and Trim Sections of this manual for details.

• This boiler must be properly vented and connected to an approved vent system in good condition. DO NOT operate boiler with the absence of an approved vent system.

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

• A clean and unobstructed chimney flue 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 efficiency.

• 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 fastener completely when service is completed.

1 Product Description, Specification and Dimensional Data

The FORCEVFO Series boiler is a cast iron oil-fired water boiler designed for closed forced circulation heating systems. This boiler must be vented by natural draft into a fireclay tile-lined masonry chimney or chimney constructed from type L vent or a factory built chimney that complies with the type HT requirements of UL103. An adequate supply of air for combustion, ventilation and dilution of flue gases must be available in the boiler room.

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FORCEVFO Installation & Service Manual

1 Product Description, Specification and Dimensional Data (continued)

Table 1A: Dimensional Data

Boiler Series

Dimensions

"A" "B" "C" Round in Dia.

Approx.

Water Content

Gallons

FORCEVFO-3 17-3/8" 8-1/4" 5-7/8" 16 6

FORCEVFO-5 27-3/8" 13-3/8" 7-7/8" 24 8

Maximum Working Water Pressure: 30 PSI Shipped from Factory, 50 PSI Optional

Table 1B: Rating Data

Boiler

Model

Burner

Capacity

GPH MBH

(1)

Heating

Capacity

(2)

Ratings

MBH MBH

Net AHRI

(3)

FORCEVFO-3-075 0.75 105 92 80 87.0 FORCEVFO-3-100 1.00 140 122 106 86.3 FORCEVFO-4-120 1.20 168 148 129 87.0 FORCEVFO-4-150 1.50 210 182 158 86.0 FORCEVFO-5-175 1.75 245 214 186 86.4 FORCECFO-5-190 1.90 266 231 201 86.0

(1)

MBH refers to thousands of BTU per hour.

(2)

Based on standard test procedure prescribed by the United States Department of

Energy at combustion conditions of 13.0% CO2.

(3)

Net AHRI Ratings are based on piping and pickup allowance of 1.15 for water.

Recommended Minimum Chimney

Rectangle

in. x in.

Height ft.

8 x 8 15FORCEVFO-4 22-3/8" 10-7/8" 6-7/8" 20 7

AFUE

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FORCEVFO Installation & Service Manual

1 Product Description, Specification and Dimensional Data (continued)

'C'

'B'

DIA.

Figure 1-1: Water Boiler without Tankless Heater

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FORCEVFO Installation & Service Manual

1 Product Description, Specification and Dimensional Data (continued)

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Figure 1-2: Water Boiler with Rear Tankless Heater

Page 8

2 Pre-Installation

FORCEVFO Installation & 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 Figures 1-1 and 1-2.

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 SERVICE CLEARANCE of at least 24” clearance from front jacket panel for servicing and removal of front tankless heater. If boiler is equipped with a rear tankless heater, provide at least 24" service clearance on the right side of the boiler. Boiler flueways may be cleaned either from the top. Provide at least 24" clearance from the top of the boiler for cleaning flueways.

5. For minimum clearances to combustible materials. See Figure 2-1.

C. PROVIDE COMBUSTION AND VENTILATION

AIR. Local and National Codes may apply and

should be referenced.

Figure 2-1: Minimum Installation Clearances To Combustible Materials (Inches)

NOTES:

1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.

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

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

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2 Pre-Installation (continued)

FORCEVFO Installation & Service Manual

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.

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.

1. Determine volume of space (boiler room). Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the space.

Volume(ft3) = Length(ft) x Width(ft) x Height(ft)

2. Determine total input of all appliances in the space.

Add inputs of all appliances in the space and

round the result to the nearest 1000 BTU per hour.

3. Determine type of space. Divide Volume by total input of all appliances in space. If the result is greater than or equal to 50 ft3/1000 BTU per hour, then it is considered an unconfined space. If the result is less than 50 ft3/1000 BTU per hour then the space is considered a confined space.

4. For boiler located in an unconfined space of a conventionally constructed building, the fresh air infiltration through cracks around windows and doors normally provides adequate air for combustion and ventilation.

5. For boiler located in a confined space or an unconfined space in a building of unusually tight construction, provide outdoor air.

a. Outdoor air may be provided with the

use of two permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 inches. Size each opening per following:

i. Direct communication with outdoors.

Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space.

ii. Vertical ducts. Minimum free area of

1 square inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

iii. Horizontal ducts. Minimum free area of

1 square inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.

Alternate method for boiler located

within confined space. Use indoor air if

two permanent openings communicate directly with additional space(s) of sufficient volume such that combined volume of all spaces meet criteria for unconfined space. Size each opening for minimum free area of 1 square inch per 1,000 BTU per hour input of all equipment in spaces, but not less than 100 square inches.

6. Louvers and Grilles of Ventilation Ducts a. All outside openings should be screened

and louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of rain and snow.

b. Free area requirements need to consider

the blocking effect of louvers, grilles, or screens protecting the openings. If the free area of the louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area.

c. Louvers and grilles must be fixed in the

open position, or interlocked with the equipment to open automatically during equipment operation.

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3 Packaged Boiler Assembly

A. REMOVE CRATE.

1. Remove all fasteners at crate skid.

2. Lift outside container and remove all other inside protective spacers and bracing. Remove draft regulator box and miscellaneous trim bag containing safety or relief valve, and pipe fittings.

B. REMOVE BOILER FROM SKID.

1. Boiler is secured to base with 4 bolts, 2 in front and 2 in rear of shipping skid, see Figure 3-1. Remove all bolts.

2. Tilt boiler to right and to rear. Using right rear leg as pivot, rotate boiler 90° in a clockwise direction, and lower left side of boiler to floor.

Tilt boiler and remove crate skid. Care should

be exercised to prevent damage to jacket or burner.

FORCEVFO Installation & Service Manual

E. INSTALL OIL BURNER.

1. Open burner carton and remove contents. Refer to Table 15-1.

2. Place oil burner gasket on burner and align

holes.

CAUTION

Do not install burner without Gasket.

3. Remove three (3) 5/16-18 x 3/4” long cap

screws from burner swing door used for mounting burner.

4. Insert oil burner into opening of burner swing

door. Align the top slotted hole in burner flange with the top hole on the burner swing door. Install one (1) cap screw.

5. Align remaining holes and install the two (2) remaining cap screws.

F. INSTALL SAFETY OR RELIEF VALVE see

Figure 1-1.

Use ¾" NPT x 7

Safety or Relief Valve must be installed with spindle in vertical position. Pipe discharge as shown in Figures 4-2 and 4-3. Installation of the safety or relief valve must be consistent with ANSI/ ASME Boiler and Pressure Vessel Code, Section I V.

/4" nipple included in trim bag.

Figure 3-1 : Packaged Boiler Removal from Skid

CAUTION

DO NOT drop boiler. DO NOT bump boiler

jacket against floor.

C. MOVE BOILER TO PERMANENT POSITION

by sliding or walking.

D. INSPECT COMBUSTION CHAMBER TARGET

WALL.

1. Open burner swing door.

2. Using a flashlight, inspect the rear target wall. The target wall should be rigidly secured to the

rear boiler section.

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.

G. PACKAGED WATER BOILERS WITH

CIRCULATORS. If your boiler build comes with

factory supplied circulator and circulator is to be mounted in supply piping connected directly to

1½" boiler supply tapping.

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4 Water Boiler Piping and Trim

FORCEVFO Installation & Service Manual

NOTICE Failure to pipe boiler as specified in this

manual may result in excessive system noise, water line fluctuations and water carry over.

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 pipe.

U.S. Boiler Company 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 pressure drop of all radiators, baseboard and radiant tubing and all connecting piping must be considered.

CAUTION

Maintain minimum ½ inch clearance from hot

water piping to combustible materials.

B. CONNECT SYSTEM SUPPLY AND RETURN

PIPING TO BOILER. See Figures 4-2 and

4-3. 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 4-1. 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 boiler is used with an Indirect Domestic Water Heater, install the Indirect Water Heater as a separate heating zone. Refer to the Indirect Water Heater Installation, Operating, and Service Instructions for additional information.

4. 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 4-2 and 4-3 in order to regulate water flow for maintenance of higher boiler water temperature.

WARNING

The use of a low water cut-off device, while

not required unless radiation level is below the boiler, is highly recommended.

5. If a Low Water Cut-Off (LWCO) 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. Refer to Appendix A at the rear of this manual.

6. If it is required to perform a long term pressure test of the hydronic system, the boiler should first be isolated to avoid a pressure loss due to the escape of air trapped must first be removed from the boiler.

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4 Water Boiler Piping and Trim (continued)

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.

FORCEVFO Installation & Service Manual

Figure 4-1: Recommended Piping for Combination Heating and Cooling (Refrigeration) System

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4 Water Boiler Piping and Trim (continued)

FORCEVFO Installation & Service Manual

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Figure 4-2: Recommended Water Piping for Circulator Zoned Heating System - Supply Side Circulators

Page 14

4 Water Boiler Piping and Trim (continued)

FORCEVFO Installation & Service Manual

Figure 4-3: Recommended Water Piping for Zone Valve Zoned Heating System - Supply Side Circulator

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Page 15

5 Tankless and Indirect Water Heater Piping

FORCEVFO Installation & Service Manual

A. CONNECT TANKLESS HEATER PIPING as

shown in Figure 5-1. See Table 5-2 for Tankless Heater Rating.

WARNING

Install automatic mixing valve at tankless heater

outlet to avoid risk of burns or scalding due to excessively hot water at fixtures. Adjust and maintain the mixing valve in accordance with the manufacturer's instructions. DO NOT operate tankless heater without mixing valve.

THE FOLLOWING GUIDELINES SHOULD BE FOLLOWED WHEN PIPING THE TANKLESS HEATER:

1. FLOW REGULATION — If flow through the heater is greater than its rating, the supply of adequate hot water may not be able to keep up with the demand. For this reason a flow regulator matching the heater rating should be installed in the cold water line to the heater. The flow regulator should preferably be located below the inlet to the heater and a minimum of 3’ away from the inlet so that the regulator is not subjected to excess temperatures that may occur during “off” periods when it is possible for heat to be conducted back through the supply line. The flow regulator also limits the flow of supply water regardless of inlet pressure variations in the range of 20 to 125 psi.

2. TEMPERING OF HOT WATER — Installation of an automatic mixing valve will lengthen the delivery of the available hot water by mixing some cold water with the hot. This prevents the possibility of scalding hot water at the fixtures. In addition, savings of hot water will be achieved since the user will not waste as much hot water while seeking a water temperature. Higher temperature hot water required by dishwashers and automatic washers is possible by piping the hot water from the heater prior to entering the mixing valve. The mixing valve should be “trapped” by installing it below the cold water inlet to heater to prevent lime formation in the valve. Refer to Figure 16A.

3. FLUSHING OF HEATER — All water contains some sediment which settles on the inside of the coil. Consequently, the heater should be periodically back washed. This is accomplished by installing hose bibs as illustrated and allowing water at city pressure to run into hose bib A, through the heater, and out hose bib B until the discharge is clear. The tees in which the hose bibs are located should be the same size as heater connections to minimize pressure drop.

4. HARD WATER — A water analysis is necessary to determine the hardness of your potable water. This is applicable to some city water and particularly to well water. An appropriate water softener should be installed based on the analysis and dealer’s recommendation. This is not only beneficial to the tankless heater but to piping and fixtures plus the many other benefits derived from soft water.

Use street elbow fittings in tankless in and out

connections to assure adequate clearance of piping.

CAUTION

Use of hard water with a tankless coil will, over

a short period of time, reduce the output of the coil, reduce flow due to increased pressure drop and reduce the useful life of the coil.

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FORCEVFO Installation & Service Manual

5 Tankless and Indirect Water Heater Piping (continued)

Figure 5-1: Schematic Tankless Heater Piping

Table 5-2: Tankless Heater Data

Boiler

Model

FORCEVFO-3-075 3.00 4.7 FORCEVFO-3-100 3.25 5.6 FORCEVFO-4-120 3.75 7.2 FORCEVFO-4-150 4.00 8.0 FORCEVFO-5-175 4.25 8.8 FORCEVFO-5-190 4.75 9.6

Rating

(Gal/Min)

Drop (PSI)

Pressure

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Page 17

FORCEVFO Installation & Service Manual

6 Venting

WARNING

Vent this boiler according to these instructions. Failure to do so may cause products of combustion to enter

the home resulting in severe property damage, personal injury or death.

• Insufficient Combustion Air Supply may result in the production and release of deadly carbon monoxide (CO) into the home which can cause severe personal injury or death.

• Improper venting may result in property damage and the release of flue gases which contain deadly carbon monoxide (CO) into the home, which can cause severe personal injury, death, or substantial property damage.

• Inspect existing chimney and vent connector for obstructions and deterioration before installing boiler. Failure to clean or replace perforated pipe or chimney liner will cause severe injury or death.

• Do not de-rate the appliance. Failure to fire the boiler 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.

A. GENERAL VENTING GUIDELINES

1. Chimney venting is an important part of a safe and efficient oil fired appliance system. Contact your local fire and building officials on specific 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 for installations in the United States.

2. The safe venting of oil fired boilers is dependant on many factors. Some of these factors include:

a. sufficient draft during the entire heating season

to allow for the safe discharge of combustion by-products and;

b. suitable corrosion protection in the event of

condensing flue gases. Only a trained and qualified contractor may install this product.

3. The FORCEVFO shall be vented into any of the following:

a. Masonry or metal chimney. Build and install

in accordance with local buildings codes; or local authority having jurisdiction; or “Standards for Chimney, Fireplace, Vents, and Solid Fuel Burning Appliances”, ANSI/ NFPA 211 and/or National Building Code of Canada. Masonry chimney must be lined with listed chimney system. Listed clay flue lined masonry chimneys meet venting requirements.

• External chimneys are more susceptible to flue gas condensation due to colder outside air temperatures. To prevent corrosion due to flue gas condensation, use a listed corrosion-resistant metal liner in chimney.

• Oversized chimneys are more susceptible to flue gas condensation. To reduce the likelihood of flue gas condensation and ensure proper draft, use a properly sized listed metal liner in oversized chimney.

4. Chimney Inspection – Prior to the installation of any new or replacement fuel burning equipment the chimney shall be inspected by a qualified 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 qualified person in accordance with the requirements of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances.

a. Loose Mortar – Loose mortar could be an

indication of a prior history of condensing flue 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 or CSA B139.

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 specified 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.

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6 Venting (continued)

FORCEVFO Installation & Service Manual

Figure 6-1: Recommended Vent Pipe Arrangement and Chimney Requirements

Figure 6-2: Proper and Improper Locations of Draft Regulator

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6 Venting (continued)

d. Clean Chimney – Chimney shall be free of all

loose debris.

5. Draft Regulator – the draft regulator supplied with the boiler (or equivalent) must be used with this appliance. Refer to Figures 6-1 and 6-2.

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.

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 flue gases into the living space. If the chimney is to be re-lined use the recommendations in NFPA 31, Appendix E.

2. Vent Connector shall be any of the following and of the same size as the outlet of boiler.

a. Type L or a factory built chimney material

that complies with the Type HT requirements of ANSI/UL 103. Install in accordance with listing and manufacturer’s instructions.

b. Steel pipe having resistance to corrosion

and heat with a minimum wall thickness of 24 Gauge (0.024”).

DANGER

Any sign 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.

FORCEVFO Installation & Service Manual

2. Minimum Draft Overfire – The draft induced by a chimney must create at least a pressure of -0.02 inches water column (“ w.c.). The pressure at the canopy cannot be positive since this could create a condition that allows flue gas by-products to escape from the draft regulator. A negative pressure reading up to -.03 inches water column is acceptable for proper operation.

STACK TEMPERATURE

1. The temperature of the flue gases has a significant 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 flue 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 sufficient 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 flue gas condensate, must be relined according to NFPA 31 (United States). 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 sufficient draft and to protect against corrosion caused by flue gas condensate.

DRAFT

1. The natural draft generated through a chimney is dependent on several factors including, chimney height, temperature of flue gases, cross section area of chimney, chimney wall insulation value, dilution air and total volume of flue gases, to name a few. Make sure that the boiler has been running for at least 5 minutes before measuring the draft.

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7 Electrical

FORCEVFO Installation & Service Manual

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.

• The primary control may be damaged or may not function properly if 120 volt power supply is NOT wired into control as follows:

The 120V interrupted hot (black) wire must be

connected to the primary control black wire, the 120V neutral (white) wire must be connected to the primary control white wire and the 120V constant hot (red) wire must be connected to the primary control red wire.

7. Wiring should conform to Figures 7-1 through 7-2.

B. INSTALL A ROOM THERMOSTAT on an inside

wall about four feet above floor. Never install thermostat on an outside wall or where it will be influenced by drafts, hot or cold water pipes, lighting fixtures, television, rays of the sun or near a fireplace. 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 7-1 thru 7-2 for desired system and heat anticipator setting. If system tends to overheat above the thermostat's temperature setting, reduce heat anticipator settings 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.

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 mail 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.

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7 Electrical (continued)

FORCEVFO Installation & Service Manual

110547-01 - 4/20

Figure 7-1: Schematic Wiring Diagram, Water Boiler, Hydrolevel Hydrostat (All Burners)

Page 22

7 Electrical (continued)

FORCEVFO Installation & Service Manual

Figure 7-2: Schematic Wiring Diagrams For All Burner Options with Various Oil Primary Controls

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Page 23

8 Oil Piping

A. GENERAL

1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping.

2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is recommended for the firing rates below 1.0 GPH to prevent nozzle fouling.

3. Use Flared fittings only. Cast iron fittings cannot be used.

NOTICE DO NOT use compression fittings.

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 for Installations in the United States and CSA B139-04 for Installation in Canada.

4. Use of a high efficiency micron filter (Garber or equivalent) in addition to a conventional filter 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.

FORCEVFO Installation & Service Manual

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 singlestage 3450 RPM fuel units with the bypass plug removed for single-pipe installations.

2. The single-stage fuel unit may be installed single-pipe with gravity feed or lift. Maximum allowable lift is 8 feet. See Figure 8-1.

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 fixing 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.

110547-01 - 4/20

Figure 8-1: Single Pipe Oil Line

Page 24

8 Oil Piping (continued)

FORCEVFO Installation & Service Manual

C. TWO PIPE OIL LINES

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

Table 8-2 (two-stage) and Table 8-3 (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 8-4.

Table 8-2: Two-Stage Units (3450 RPM) - Two Pipe Systems

Maximum Length of Tubing

Lift "H"

(See Fig. 25)

0' 93' 100'

2' 85' 100'

4' 77' 100'

6' 69' 100'

8' 60' 100'

10' 52' 100'

12' 44' 100'

14' 36' 100'

16' 27' 100'

18' --- 76'

"H" + "R" (See Figure 27)

3/8" OD

Tubing (3 GPH)

1/2" OD

Tubing (3 GPH)

Table 8-3: Single-Stage Units (3450 RPM) - Two Pipe Systems

Maximum Length of Tubing

Lift "H"

(See Fig. 25)

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' 100'

11' 26' 100'

12' 21' 83'

13' --- 62'

14' --- 41'

"H" + "R" (See Figure 27)

3/8" OD

Tubing (3 GPH)

1/2" OD

Figure 8-4: Two Pipe Oil Lines

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Page 25

FORCEVFO Installation & Service Manual

9 System Start-Up

WARNING

All 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 firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed.

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. Confirm 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.

. FILL HEATING SYSTEM WITH WATER.

NOTICE It is important, especially in a steam

system, to properly remove the oil and dirt from the system. Failure to clean the system can result in erratic water lines and surging.

CLEAN HEATING SYSTEM if boiler water or

condensate return water is dirty or if erratic water lines or surging exist after a few days of boiler operation.

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 multi-zoned system installed as per Figures 4-2 and 4-3, to remove air from system when filling: 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 piping.

(Note - Terminate hose in five gallon bucket

at a suitable floor 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 overflow from bucket until

discharge from hose is bubble free for 30 seconds.

h. When zone 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 filling the

system until the pressure gauge reads 12 psi. Close shut-off 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 safety or relief valve.

NOTICE If make-up water line is equipped with

pressure reducing valve, system will automatically fill to 12 psi. Follow fill valve manufacturer's instructions.

j. Open full port ball valve in boiler system

piping. k. Remove hose from purge valve. l. Confirm that the boiler and system have no

water leaks.

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 filled and oil lines have been tested.

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 Primary Control, hold button for one (1) second and release to reset primary control.

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Page 26

9 System Start-Up (continued)

3. CHECKOUT Put the system into operation and observe

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

E. ADJUST OIL BURNER BEFORE STARTING.

1. CHECK BURNER SETTINGS and readjust if necessary, see Burner Specifications, Table 15-1 at the rear of this manual.

F. START OIL BURNER.

1. Open vent fitting on fuel pump.

2. TURN ‘ON’ BURNER service switch and allow burner to run until oil flows from vent fitting in a SOLID stream without air bubbles for approximately 10 seconds.

3. Close vent fitting and burner flame should start immediately after prepurge is completed. Prepurge prevents burner flame until 10 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.

4. 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.

b. Locate oil pressure adjusting screw and

turn screw to obtain proper pump pressure, refer to Table 15-1 at the rear of this manual.

c. To check the cutoff 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. Remove the gauge and install bleeder port

and/or reconnect the nozzle port line.

G. ADJUST OIL BURNER WHILE OPERATING.

(flame present)

1. SET ROOM THERMOSTAT about 10°F below room temperature.

2. PRESS RED RESET BUTTON on Oil Primary Control and release.

3. READJUST THE HEAD SETTING only if necessary.

FORCEVFO Installation & Service Manual

4. ADJUST DRAFT REGULATOR for a draft of

-0.02" (water gauge) over the fire after chimney has reached operating temperature and while burner is running.

WARNING

DO NOT loosen or remove any oil line fittings

while burner is operating.

5. READJUST THE AIR SETTING on the burner for a light orange colored flame while the draft over the fire is -0.02". Use a smoke tester and adjust air for minimum smoke (not to exceed #1) with a minimum of excess air. Make final check using suitable instrumentation to obtain a CO

of 11.5 to 13.0% with draft of -0.02" (water

gauge) in fire box. These settings will assure a safe and efficient operating condition. If the flame appears stringy instead of a solid fire, try another nozzle of the same type. Flame should be solid and compact. After all adjustments are made, recheck for a draft of -0.02" over the fire.

6. FLAME FAILURE

The FORCEVFO boiler controls operate the

burner automatically. If for unknown reasons the burner ceases to fire 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 XIII, 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.

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.

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Page 27

9 System Start-Up (continued)

FORCEVFO Installation & Service Manual

2. IF NOZZLE CONTINUES TO DRIP, repeat Paragraph H, No. 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.

2. VERIFY OIL PRIMARY CONTROL FEATURES using procedures outlined in Instructions furnished with control or instructions provided with burner.

3. CHECK HIGH LIMIT

e. Check operating control on boiler

applications equipped with tankless heater(s). With burner off, draw hot water until burner starts, then turn off hot water and check burner shut-down.

J. IF CONTROLS MEET REQUIREMENT outlined

in Paragraph I.

1. Allow boiler to operate for approximately 30 minute, confirm the boiler and system have no leaks.

K. IF CONTROLS DO NOT MEET

REQUIREMENTS outlined in Paragraphs I-1

thru I-6, replace control and repeat checkout procedures.

Figure 9-1: Adjusting Fuel Pump Pressure

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.

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Page 28

10 Operating

FORCEVFO Installation & Service Manual

A. HydroStat 3250 PLUS SEQUENCE OF OPERATION

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 prevent 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.

1. Setting the Control a. Setting the High Limit: The high limit is

factory set at 190F. To adjust, turn the HI TEMP Dial A until the desired setting is displayed. (Setting range: 100-220F).

b. Setting the Low Limit: The low

limit is designed to maintain temperature in boilers equipped with tankless coils used for domestic hot water. The low limit is factory set to OFF. Prior to adjusting, remove the jumper (not equipped on all units) B. Then turn the LP TEMP Dial C clockwise until the desired temperature is displayed. For proper operation, the low temperature limit setting should be least 10 below the high limit setting. NOTE: For cold start operation, the low limit must be turned OFF.

IMPORTANT: If low limit temperature cannot be set above 140F, remove jumper B. (Setting range: OFF or 110 -200F).

c. Setting the Economy Feature: The

Economy Feature is factory set for a 1 zone heating system. To adjust, turn the ECONOMY Dial D until the number

displayed equals the number of heating

zones. Do not include indirect water heaters in the number of heating zones. The Economy Feature conserves fuel by reducing boiler temperature (see “How Thermal Targeting Works”.

If the heating system is unable to

supply needed heat to the house, the ECONOMY Dial should be turned lower setting (example: In a three zone house, turn the dial to 2 or 1.) Conversely, if the boiler provides adequate heat, added fuel savings can be achieved

by selecting a higher setting (example:

4 or 5). If the heating and indirect water heater signals were not separated when wiring the control, the Economy Feature should be turned OFF to ensure the boiler supplies adequate temperature to heat the indirect tank.

d. Setting the Zone/Indirect Switch: See

WIRING.

Setting

Off

Disables economy function. Will allow boiler to re until hi-limit temp is reached and re-re with a 10 subtractive di󰀨erential

Provides lowest level of fuel savings. Use this setting only if the house does not stay warm at higher settings.

Recommended setting for single zone systems

Recommended setting for Two zone systems

Recommended setting for Three zone systems

Recommended setting for Four zone systems

Recommended setting for Five zone systems

Provides highest level of fuel savings

e. Optional Features: NOTE: The program

Mode-Pro - is accessed by turning the LP TEMP dial to position just above Off.

2. Thermal Pre-Purge: Thermal Pre-Purge is designed to maximize boiler efficiency. When activated, the control will supply latent heat that may remain in the boiler from a previous run cycle to the heating zone that is now calling. The control monitors how quickly the boiler temperature is declining and activates the burner only when it determines that the latent heat is insufficient to satisfy the call. During the purge cycle, the display will indicate Pur. This feature works with single-zone and multi-zone heating systems utilizing circulators or zone valves. No change in wiring is needed.

To activate Thermal Pre-Purge

• Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro.

• Turn the HI TEMP dial to select feature 1.

• Push the Test/Setting Button to turn Thermal Pre-Purge ON or OFF.

• Reset LO TEMP and HI TEMP settings to desired temperatures.

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Page 29

10 Operating (continued)

3. Degrees Fahrenheit or Celsius: The control has the ability to operate in degrees Fahrenheit or Celsius. When operating in Celsius, a c will appear in the display next to the temperature when ever the temperature is below 100

degrees.

To change between degrees Fahrenheit and degrees Celsius

• Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro.

• Turn the HI TEMP dial to select feature 2.

• Push the Test/Setting Button to c for Celsius or F for Fahrenheit.

• Reset LO TEMP and HI TEMP settings to desired temperatures.

4. Manual Reset Low Water Cut-Off: The low water cut-off operation on the HydroStat can be set to operate in automatic (default) or manual reset mode. When in manual reset mode, the control will shut-down the burner immediately when low water condition is detected. If the low water condition is sustained for 30 seconds, the low water light will blink,indicating that the control has locked out the burner. The control can only be reset by pushing the Test Settings button on the top of the control. The manual reset feature meets CSD-1 code requirements.

IMPORTANT: The system must be checked by a qualified heating professional prior to resuming operation.

WARNING: DO NOT ADD WATER UNTIL THE BOILER HAS FULLY COOLED.

To activate Manual Reset LWCO mode

• Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro

• Turn the HI TEMP dial to select feature 3

• Push the Test/Setting Button to A for Automatic Reset Mode

• Reset LO TEMP and HI TEMP settings to desired temperatures. To Test the Manual Reset Feature: Press and hold the Test/Settings button located on the top of the control for 30 seconds to simulate a low water condition. After 30 seconds, the Low Water light will blink indicating that the control is locked out. To reset the lock-out condition, press the Test/ Setting button momentarily.

FORCEVFO Installation & Service Manual

5. Circulator Activation Options When in the default mode, the HydroStat

activates the circulator (C1/C2 contacts) on calls to TT. The control can be programmed to activate the circulator on calls to ZC/ZR in place of, or in addition to TT.

To change how the Circulator is activated

• Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro.

• Turn the HI TEMP dial to select feature 4.

• Push the Test/Setting Button to select. between the following options: A - Circulator on TT call only b - Circulator on ZC/ZR calls C - Circulator on both TT & ZC/ZR calls

• Reset LO TEMP and HI TEMP settings to desired temperatures.

6. Circulator Hold Off (Enhanced Condensing Protection) To reduce the potential for condensing, On a call for heat the control will allow the boiler to heat to 125F prior to energizing the circulator. Once energized, the circulator will remain on for the duration of the heating call unless the boiler temperature drops below 115F. If this occurs, the circulator will re-energize when the boiler returns to 125F. Circulator Hold Off will expire after 15 minutes.

To activate Circulator Hold Off

• Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro.

• Turn the HI TEMP dial to select feature 5.

• Push the Test/Setting Button to Circulator Hold Off ON or OFF.

• Reset LO TEMP and HI TEMP settings to desired temperatures.

7. Setting the Well Type (Elctro-Well vs. Standard Immersion Well)

When used to replace older temperature only controls, the HyrdroStat can be installed on the existing well. (The Hydrolevel Elctro Well is required to activate low water cut-off operation. Older wells may contain hardened heat transfer grease or other contaminants that could interfere with metal-to-metal continually between the sensor head and the inside of the well. Insufficient contact could lead to false low water conditions and burner shut downs. Setting the well type to Standard Well prevents the possibility of this occurring.

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Page 30

10 Operating (continued)

To change the well type

• Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro.

• Turn the HI TEMP dial to select feature 8.

• Push the Test/Setting Button to select A for Electro-Well or b for Standard Well. NOTE: To ensure that the low water cut-off is always active when the control is installed on an ElectroWell, setting b will ONLY be available when installed on a standard well. The HydroStat sensor checks to determine if a standard well is used by looking for low resistance to ground, a condition that can only exist with a standard well. If you are installing on a standard well and either Low Water LED’s are on, setting b will not be available. Check to see if the inside of the well tube is badly oxidized or contaminated with heat transfer grease. It may be necessary to clean the well to allow for setting b to be selected (See Troubleshooting Guide for more information).

8. High Limit Differential When the Economy feature is on, the

control’s Thermal Targeting feature actively sets varying differentials based on system conditions. This option allows for selecting a 10, 20 or 30 degree fixed differential when the Economy feature is turned OFF. These optional differential settings are subtractive from the HIGH LIMIT setting. Note: If the Economy feature in on, this setting will be overridden by the control’s Thermal Targeting function.

To change the high limit differential

• Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro.

• Turn the HI TEMP dial to select feature 9.

• Push the Test/Setting Button to select a high limit differential of 10, 20, or 30.

FORCEVFO Installation & Service Manual

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Page 31

10 Operating (continued)

FORCEVFO Installation & Service Manual

Dial Setting Feature Options Description

1 Thermal Pre-Pruge

2 Fahrenheit or Celsius

4 Circulator Options

5 Circulator Hold Off

8 Well Type

9 High Limit Differential

dEF

LWCO Manual or

Automatic Reset

Not available on this

control

Not available on this

control

Restore Factory De-

faults

OFF

NOTE: If the HydroStat is factory-equipped on a boiler, some options may be set differently from the default settings. Not all features are available on older HydroStat models.

9. Restore Factory Default Settings

To restore all features to the factory default settings (see following chart for default settings)

a. Turn the LO TEMP dial to access the Program Mode - indicated in the display as Pro b. Turn the HI TEMP dial to select feature dEF c. Push the Test/Setting Button to Y to reset all features to the default settings d. Reset LO TEMP and HI TEMP settings to desired temperatures.

10. LED Legend and Test/Settings Button a. TEMP ACTIVE Indicates that the Fuel Smart HydroStat control is powered and that the temperature function is active. b. TEMP HI TEMP Illuminates when the boiler water temperature reaches the high limit setting. It will remain lit until the water temperature falls 10. The Fuel Smart HydroStat prevents burner operation while this LED is on. See Differential explanation.

A b

10 20 30

Y N

Default Setting

Purge Inactive

Purge Active

Degrees Fahrenheit

Degree Celcius

Automatic Reset

Manual Reset

Circulator operation on TT call only Circulator operation on ZC/ZR call only Circulator operation on call from either

Circulator Hold Off - Active

Circulator Hold Off - Inactive

Hydrolevel Electro-Well

Standard Immersion Well

10 Differential 20 Differential 30 Differential

Restore Defaults

Do Not Restore Defaults

OFF

c. LWCO ACTIVE Indicates that the low water cut-off (LWCO) function of the Fuel Smart HydroStat is active. When the control is installed with a Hydrolevel Electro-WellTM, this LED will be on at all times when the control is powered. IMPORTANT: If the control is installed with a well other than the Elctro-WellTM, this LED will no illuminate indicating that the control is not providing low water cut- off functionality. d. LWCO LOW WATER Indicates that the boiler is in a low water condition. The HydroStat control will prevent burner operation during this condition. If the LOW WATER light is blinking, the control has been programmed to provide lockout protection in the event a low water condition is detected (see Manual Reset Low Water Cut-Off). Pressing the TEST/ SETTINGS button will reset the control. IMPORTANT: The system must be checked by a qualified heating professional prior to resuming operation.

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Page 32

10 Operating (continued)

FORCEVFO Installation & Service Manual

WARNING

Allow the boiler to fully cool before adding water.

e. ECONOMY ACTIVE Indicates that the Thermal Targeting function is active and the Fuel Smart HydroStat will reduce boiler temperature to conserve fuel. The Economy feature is activated using the ECONOMY dial. (See “How Thermal Targeting Works” for more information). f. ECONOMY TARGET When the Economy feature is active, the Fuel Smart HydroStat continually sets target temperature below the high limit setting to maximize fuel efficiency. When the boiler water reaches the target temperature, the LED illuminates and the burner will shut down. The boiler water will continue to circulate and heat the house as long as the thermostat call continues. The LED will stay lit until the boiler temperature drops below the differential set point at which point the boiler will be allowed to fire again. See Differential explanation. NOTE: This LED illuminates regularly during normal boiler operation. g. TEST/TESTING Button To Test Low Water Cut-Off: Press and hold the Test/Settings button for 5 seconds. The display will read LCO.

LWCO TEST LCO

The red Low Water light should illuminate and the burner circuit (B1 and B2) should de-energize. NOTE: The control must be installed with a Hydrolevel Electro-WellTM for low water cut-off functionality. To View Current Settings: Press and release the Test/ Settings Button in short intervals to sequentially display the following settings:

HIGH LIMIT SETTING HL

▼

LOW LIMIT SETTING LL

▼

ECONOMY SETTING ECO

▼

CURRENT TARGET TEMPERATURE 000

The display will return to boiler temperature (default) if

Test/Settings Button is not pressed for 5 seconds.

110547-01 - 4/20

Page 33

10 Operating (continued)

Important Product Safety Information:

Refractory Ceramic Fiber Product

Some boiler components 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:

FORCEVFO Installation & Service Manual

WARNING

• 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 air-purifying respirator equipped with 100-series particulate filter, as a minimum

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Dampen RCF to be removed with light water spray to prevent fibers from becoming airborne.

• 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.

110547-01 - 4/20

Page 34

11 Maintenance and Service Instructions

FORCEVFO Installation & Service Manual

A. MAINTENANCE OF LOW WATER CUT-OFF

DEVICES

WARNING

Probe and float type low water cut-off devices

require annual inspection and maintenance.

1. PROBE TYPE LOW WATER CUT-OFF Although these devices are solid state in their

operation, the probe is exposed to possible contamination in the boiler water and subject to fouling.

It is important to physically remove the probe

from the boiler tapping annually and inspect that probe for accumulation of scale or sediment.

Follow these steps to inspect, clean and/or

replace the probe: a. Turn off electric service to the boiler.

b. Drain boiler water to a level below the

tapping for the probe.

c. Disconnect wiring connections between the

low water cut-off control and the probe.

d. Remove the low water cut-off control from

the probe.

DANGER

Assure that the boiler is at zero pressure before

removing the LWCO probe. DO NOT rely on the pressure gauge to indicate that the boiler is at zero pressure. 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.

e. Unscrew the probe from the boiler tapping. f. Inspect that portion of the probe that is

exposed to the boiler water for a scale or sediment buildup.

g. Light deposits may be removed by wiping

the probe with a damp cloth. Wiping the probe with a cloth soaked in vinegar will remove more tenacious lime deposits. The most stubborn deposits may be removed from the probe by using a diluted amount, 3 parts of water to 1 part of phosphoric acid (H

Exercise caution when handling phosphoric

acid and follow the instruction label on its container.

h. Clean the pipe threads of the probe to

remove old, hardened pipe dope and other foreign matter.

2PO4

CAUTION

i. Apply a moderate amount of good quality

pipe dope to the pipe threads on the probe, leaving the two end threads bare. DO NOT

use PTFE (Teflon) tape. j. Screw the probe into the boiler tapping. k. Mount the low water cut-off control on the

probe. l. Reconnect the control to probe wiring. m. Fill the boiler to its normal waterline. n. Add boiler water treatment compound as

needed (refer to Paragraph B.). o. Restore electric service to the boiler. p. Fire burner to bring the water in the boiler to

a boil to drive off free oxygen. q. WARNING — BEFORE RETURNING

BOILER TO SERVICE: Follow the low water

cut-off check out procedure.

B. BOILER AND SYSTEM CLEANING

INSTRUCTIONS FOR TROUBLE FREE OPERATION

NOTICE Check with local authorities or consult

local water treatment services for acceptable chemical cleaning compounds.

1. WATER BOILERS a. 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.

b. 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.

i. Remove relief valve using extreme care

to avoid damaging it.

ii. Add an appropriate amount of

recommended boil out compound.

iii. Replace relief valve. iv. Fill the entire system with water.

v. Start firing the boiler. vi. Circulate the water through the entire

system.

vii. Vent the system, including the radiation. viii. Allow boiler water to reach operating

temperature, if possible.

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Page 35

FORCEVFO Installation & Service Manual

11 Maintenance and Service Instructions (continued)

ix. Continue to circulate the water for a few

hours.

x. Stop firing the boiler. xi. Drain the system in a manner and

to a location that hot water can be discharged with safety.

xii. Remove plugs from all available returns

and wash the water side of the boiler as thoroughly as possible, using a highpressure water stream.

xiii. Refill the system with fresh water.

c. Add appropriate boiler water treatment

compounds as recommended by your

qualified water treatment company. d. Make pH or Alkalinity Test. After boiler and system have been cleaned

and refilled 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

specific 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 appropriate water treatment

chemicals, if necessary, to bring the pH

within the specified range. With this lower

level of protection, care must be exercised

to eliminate all of the free oxygen in the

system. e. Boiler is now ready to be put into service.

C. EXCESSIVE MAKE-UP WATER

A leaky system will increase the volume of

make-up water supplied to the boiler which can significantly 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 cast iron. When this happens the cast iron in that area gets extremely hot and eventually cracks. The presence of free oxygen or chloride salts in the boiler corrodes the cast iron from the inside. More make-up water and higher concentrations of contaminants damage the boiler sooner. Our warranty does

not cover corrosion and sediment-related 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.

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

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

3. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section IX, Paragraphs A through K.

IMPORTANT

IF, DURING NORMAL OPERATION, IT IS

NECESSARY TO ADD MORE WATER THAT INDICATION BELOW, CONSULT A QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS.

Boiler

Series FORCEVFO-3 3.00 4.7 FORCEVFO-4 3.25 5.6 FORCEVFO-5 3.75 7.2

110547-01 - 4/20

Gallons Per

Month

Gallons Per

Year

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 36

FORCEVFO Installation & Service Manual

12 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 firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed.

A. CLEAN THE FLUEWAYS (See Figure 12-1).

1. For cleaning from the top: a. Remove as much vent pipe as necessary

to allow removal of the jacket top panel and

canopy. b. Remove the jacket top panel. c. Remove flue baffles. d. Remove the canopy, being careful not to

damage the gasket.

2. Using a 1¼” diameter wire or fibre bristle brush (30” handle) clean the flueways. Brush from the top and/or side using horizontal and diagonal strokes for best results. DO NOT allow brush to strike the target wall or liner in the chamber.

B. CLEAN TOP OF BOILER SECTIONS

(if cleaning from the top).

Brush and vacuum the tops of the boiler sections.

C. CLEAN THE COMBUSTION CHAMBER Using wire or fibre bristle brush, clean crown of

boiler and inside of water legs.

WARNING

DO NOT allow brush to strike target wall in the

combustion chamber.

E. REASSEMBLE BOILER

CAUTION

DO NOT start the burner unless canopy, vent

pipe, burner swing door and all flue cover plates are secured in place.

1. Insert the flue baffles.

2. Install the canopy taking care to align the gasket without blocking the flueways. If gasket is damaged, replace as needed.

3. Reinstall jacket top panel with #8 x ½" long sheet metal screws.

4. Reinstall vent pipe on canopy and secure to collar with sheet metal screws.

5. Close burner swing door. Secure door to front section with 5/16" lg. bolts.

NOTICE When securing burner swing door make sure door is drawn-in equally on both sides.

Tighten swing door hardware to provide

adequate seal around perimeter of door.

Use an alternating tightening method from right

to left side cap screw to pull door tight equally.

D. AFTER CLEANING Inspect target wall, burner

swing door insulation for signs of damage. If damaged, replace as needed.

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Page 37

12 Boiler Cleaning (continued)

FORCEVFO Installation & Service Manual

Figure 12-1: 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 flue 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 flue 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 efficiency.

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Page 38

13 Troubleshooting

FORCEVFO Installation & Service Manual

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 FORCEVFO boiler is the result of extensive testing to obtain the best flame shape and efficient 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 mass-produced 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 fire 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 fire 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 fitting. 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 fittings put on. Just make sure you get the air out before you leave.

Any air leaks in the fuel line will cause an

unstable flame and may cause delayed ignition noises. Use only flare fittings in the fuel lines.

4. GASKET LEAKS — If 11.5 to 13.0% 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 firing rate the greater effect an air leak can have on CO2 readings.

5. DIRT — A fuel filter 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 firing 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 flame and causes smoke and unburned fuel to pass out of the combustion chamber and clog the flueways 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 flame 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 flame should appear straight with no sparklers rolling up toward the crown of the chamber. If the flame 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. HIGH ALTITUDE INSTALLATIONS — Air openings must be increased at higher altitudes. Use instruments and set for 11.5 to

13.0% CO2.

10. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode settings, flame shape, air or water in the fuel lines.

110547-01 - 4/20

Page 39

13 Troubleshooting (continued)

FORCEVFO Installation & Service Manual

11. SHUT DOWN NOISE — If the flame 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 firing cycles for that air to be fully vented through the nozzle. Water in the fuel or poor flame 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, fire out of an auxiliary five 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.

B. OIL PRIMARY CONTROL (Oil Primary)

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 XI, Paragraph I, No.

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 flame out. c. Defective nozzle causing flame to be

erratic.

d. Excessive airflow or draft causing flame to

leave burner head.

e. Excessive back pressure causing flame to

be erratic.

3. Control locks out after Trial For Ignition (TFI). a. No oil to burner. b. Shorted electrodes. c. Nozzle clogged. d. Airflow 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 flame 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.

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Page 40

FORCEVFO Installation & Service Manual

THIS PAGE IS INTENTIONALLY LEFT BLANK.

110547-01 - 4/20

Page 41

FORCEVFO Installation & Service Manual

14 Service Parts

All FORCEVFO™ Series Boiler Service Parts may be obtained through your local Ferguson branch.

110547-01 - 4/20

Page 42

14 Service Parts (continued)

FORCEVFO Installation & Service Manual

Bare Boiler Assembly

110547-01 - 4/20

Page 43

14 Service Parts (continued)

FORCEVFO Installation & Service Manual

Item No.

Description

Block Assembly for Water Includes: Complete Block Assembly, Target Wall Insulation, Coil Gasket, Coil Cover Plate/Hardware

Canopy Includes: Canopy, Canopy Gasket

and Hardware

1C Canopy Gasket 110272-01 1 1 1

1G Flue Baffles 110276-01 2 3 4

Combustion Chamber Includes: Target Wall

Insulation, Combustion Chamber Blanket, Burner Door Insulation

1J Burner Swing Door 104140-01 1 1 1

Heater Cover Plates &

Gaskets

1L V1-2 Coil 6036031 1 1 1

Rear Heater

Non Heater

Rear Heater-Blank 6036032 1 1 1

Rear Heater-Trapped 6036033 1 1 1

Part

Number

110552-03 1

110552-04 1

110552-05 1

110553-03 1

110553-04 1

110553-05 1

110554-03 1

110554-04 1

110554-05 1

108471-01 1 1 1

FORCEVFO-3 FORCEVFO-4 FORCEVFO-5

110547-01 - 4/20

Page 44

14 Service Parts (continued)

FORCEVFO Installation & Service Manual

Water Boilers - Trim and Controls

110547-01 - 4/20

Page 45

14 Service Parts (continued)

FORCEVFO Installation & Service Manual

Item

No.

Description

Complete Jacket Carton for Water, Rear Heater

Complete Jacket Carton for Water, NonHeater

Temperature & Pressure Gauge, 1/4" NPT x 2-1/2"

Electro-Well (WN), 1/2" NPT x 1" 110555-01 1 1 1

Electro-Well (WT), 3/4" NPT x 4" 110556-01 1 1 1

HydroStat 3250 Plus (WN) Assembly 110557-01 1 1 1

HydroStat 3250 Plus (WT) Assembly, 3 and 4 Section

HydroStat 3250 Plus (WT) Assembly, 5 Section

Harness (WN) 110559-01 1 1 1

Harness (WT), 3 and 4 Section 110614-01 1 1

Harness (WT), 5 Section 110615-01 1

Part

Number

110573-03 1

110573-04 1

110573-05 1

110571-03 1

110571-04 1

110571-05 1

109966-01 1 1 1

110558-01 1 1

110617-01 1

FORCEVFO-3 FORCEVFO-4 FORCEVFO-5

Not

Shown

Relief Valve, Conbraco, 3/4" FIP x 3/4" FIP

Drain Valve, 3/4" NPT, ConBraCo 35-302-03 1 1 1

Circulator Flange, 1-1/2" NPT 2 2 2

Circulator Gasket

Circulator Grundfos Alpha2 1 1 1

#10-408-05 30 PSI

#10-303-07 40 PSI

#10-303-10 50 PSI

Obtain

Locally

Grundfos 2 2 2

1 1 1

110547-01 - 4/20

Page 46

FORCEVFO Installation & Service Manual

14 Service Parts (continued)

Item No. Description Part Number FORCEVFO-3 FORCEVFO-4 FORCEVFO-5

110498-03 1

Not

Shown

Beckett

Primary Control

Honeywell R7284P1080

Beckett GeniSys 7505P1515

110499-04 1

110500-05 1

103880-01 1 1 1

Obtain

Locally

1 1 1

110547-01 - 4/20

Page 47

15 Burner Specifications

Table 15-1: Beckett

FORCEVFO Installation & Service Manual

Settings

Air

Shutter

10 2 0.65 X 60B (Hago) Installed

10 0.5 1.00 x 60B (Hago) Installed

Air

Band

Nozzle Shipped

Firing

Boiler Model

FORCEVFO-3-075 0.75 FORCEVFO-3-100 1.00 5 2 0.85 x 60B (Hago) Field Provided FORCEVFO-4-120 1.20 FORCEVFO-4-150 1.50 10 6 1.25 x 60B (Hago) Field Provided FORCEVFO-5-175 1.75 V1(3) 6 6 1.50 x 45B (Hago) Installed FORCEVFO-5-190 1.90 V1(4) 8 4 1.35 x 45B (Hago) Field Provided

Rate

GPH

Burner Model

AFG

Head

(Setting)

V1(0)

Pump

Pressure

140

175

110547-01 - 4/20

Page 48

FORCEVFO Installation & Service Manual

Appendix - Aftermarket Low Water Cut Off (LWCO)

WARNING

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

connections specifically identified 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 floor 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 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 float type, due to their relative costs and the simplicity of piping for a probe LWCO.

Select the appropriate size tee using the LWCO

manufacturer’s instructions. Often, the branch connection must have a minimum diameter to 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.

How to Wire

LWCO’s are available in either 120 VAC or 24

VAC configurations. The 120 VAC configuration must be applied to 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 servicing the boiler as shown below.

How to Pipe

A “tee” is commonly used to connect the probe

LWCO in the supply or return piping, as shown below.

LWCO Location

Wiring of Typical LWCO

110547-01 - 4/20

Page 49

FORCEVFO Installation & Service Manual

Appendix - Aftermarket Low Water Cut Off (LWCO)

A 24 VAC LWCO is used primarily for gas fired

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.

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

How to Test

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Page 50

FORCEVFO Installation & Service Manual

SERVICE RECORD

DATE

SERVICE PERFORMED

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Page 51

FORCEVFO Installation & Service Manual

SERVICE RECORD

DATE

SERVICE PERFORMED

110547-01 - 4/20

Page 52

FORCEVFO Installation & Service Manual

SERVICE RECORD

DATE

SERVICE PERFORMED

110547-01 - 4/20

PROSELECT FORCEVFO-3-075E, FORCEVFO-3-100E, FORCEVFO-4-120E, FORCEVFO-4-150E, FORCEVFO-5-175E Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual