PROSELECT Force Boilers FORCESTEAM07NH Installation guide

Brand: PROSELECT Force Boilers

Model: FORCESTEAM07NH

Type: Installation guide

For service or repairs to boiler, call your heating contractor. When seeking information on boiler,

provide Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

FORCESTEAM0 _

Boiler Serial Number Installation Date

Heating Contractor Phone Number

Address

106324-04 - 4/18 Price - $5.00

INSTALLATION, OPERATING

AND

SERVICE INSTRUCTIONS

FORCESTM™ SERIES

GAS BOILER

9700609

106324-04 - 4/18

FOLLOW ALL INSTRUCTIONS and warnings

printed in this manual and posted on the boiler.

INSPECT THE BOILER ANNUALLY. To keep

your boiler safe and efficient, have a service

technician follow the Service checklist near the

end of this manual.

IF YOU ARE NOT QUALIFIED to install or service

boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of its

useful life. Be sure to protect walls, carpets, and

valuables from water that could leak from the

boiler.

PROTECT YOUR HOME IN FREEZING

WEATHER. A power outage, safety lockout, or

component failure will prevent your boiler from

lighting. In winter, your pipes may freeze and

cause extensive property damage. Do not leave

the heating system unattended during cold

weather unless alarms or other safeguards are in

place to prevent such damage

DO NOT BLOCK AIR FLOW into or around the

boiler. Insufficient air may cause the boiler to

produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the

boiler, including paint, solvents, and gasoline.

The boiler may ignite the vapors from the liquids

causing explosion or fire.

KEEP CHILDREN AND PETS away from hot

surfaces of the boiler, boiler piping, and vent

pipe.

CARBON MONOXIDE (CO) is an odorless,

deadly gas that may be introduced into your

home by any malfunctioning fuel-burning product

or vent system failure. Consider installing CO

alarms near bedrooms in all levels of the building

to warn you and your family of potential CO

exposure.

WARNINGS FOR THE HOMEOWNER

106324-04 - 4/18

READ THIS ENTIRE MANUAL before attempting

installation, start-up, or service. Improper

installation, adjustment, alteration, service,

or maintenance may cause serious property

damage, personal injury, or death.

DO NOT DISCONNECT PIPE FITTINGS on

the boiler or in the heating system without first

verifying that the system is cool and free of

pressure and that your clothing will protect you

from a release of hot water or steam. Do not rely

solely on the boiler’s temperature and pressure

gage when making this judgment.

USE PROPER PERSONAL PROTECTION

EQUIPMENT when servicing or working near the

boiler. Materials of construction, flue products,

and fuel contain alumina, silica, heavy metals,

carbon monoxide, nitrogen oxides, and/or

other toxic or harmful substances that can are

hazardous to health and life and that are known

to the State of California to cause cancer, birth

defects, and other reproductive harm.

INSTALL ALL GUARDS, cover plates, and

enclosures before operating the boiler.

SIZE THE BOILER PROPERLY relative to the

design heat load or, if using domestic hot water

priority, the peak hot water load, whichever

is larger. A grossly oversized boiler will cycle

excessively and this will lead to premature failure

of the boiler and its components. Our warranty

does not apply to damage from excessive

cycling.

ADHERE TO ALL LOCAL CODE

REQUIREMENTS. Contact your local code

inspector prior to installation. In the absence of a

local code, adhere to the National Fuel Gas Code

ANSI Z223.1/NFPA 54.

ALL WIRING must comply with the National

Electrical Code ANSI/NFPA 70.

WARNINGS FOR THE INSTALLER

106324-04 - 4/18

 TheFORCESTMseriesboilersarelowpressurecastirongasredsteamboilersdesignedforuseinclosedsteam

heatingsystems.TheseboilersareCategoryIdraftdiverterequippedappliances,whichmustbeventedbynaturaldraftusing

alinedmasonryorlistedmetalchimneysystem.Anadequatesupplyofairforcombustion,ventilationanddilutionofue

gasesmustbeavailableintheboilerroom.Theseboilersarenotdesignedforuseinprocessorother“open”steamsystems

TABLE OF CONTENTS

I. Product Description.................................................................................... 4

II. Specications............................................................................................ 5

III. Pre-Installation........................................................................................... 6

IV. Locating the Boiler..................................................................................... 6

V. Air for Combustion & Ventilation................................................................ 7

VI. Venting....................................................................................................... 8

VII. Gas Piping................................................................................................. 10

VIII. System Piping............................................................................................ 11

IX. Indirect Water Heater Piping...................................................................... 14

X. Electrical.................................................................................................... 15

XI. System Start-Up........................................................................................ 20

XII. Service Instructions................................................................................... 25

XIII. Troubleshooting.......................................................................................... 29

XIV. Repair Parts.............................................................................................. 33

Appendix A - Tapping Locations................................................................. 44

I. Product Description

106324-04 - 4/18

TABLE 1: FORCESTM SPECIFICATIONS

II. Specications

FIGURE 1: FORCESTM BOILERS - GENERAL CONFIGURATION

Boiler Model

Approx.

Shipping

Weight

Lbs.

Dimensions (in inches)

Recommended Min.

Round

Chimney Size

(Diameter x Height)

(1)

Gas

Conn.

(NPT)

Water Volume

(Gal.)

'A' 'B' 'C' 'D'

Steam

Boiler

(2)

FORCESTM03 350 12¾

40-7/16

4 4" x 15 ft.

1/2"

5.1 3.9

FORCESTM04 420 16 5 5" x 15 ft. 6.5 5.0

FORCESTM05 485 19¼

6 6" x 15 ft.

7.9 6.1

FORCESTM06 555 22½ 9.3 7.2

FORCESTM07 620 25¾

30 7 7" x 15 ft. 3/4"

10.7 8.3

FORCESTM08 690 29 12.1 9.4

(1) 15' chimney height is from bottom of Draft Hood opening to top of Chimney.

(2) Steam boiler's "steamable water volume": water volume from NWL (normal water level) to low water cutoff level.

Heating Surface: 4.35 sq. ft. per ueway (steam); 5.72 sq. ft. per ueway (water)

106324-04 - 4/18

1)  Safe,reliableoperationofthisboilerdependsuponinstallationbyaprofessionalheatingcontractorinstrictaccordance

withthismanualandtherequirementsoftheauthorityhavingjurisdiction.

• Intheabsenceofanauthorityhavingjurisdiction,installationmustbeinaccordancewiththismanualandthe

National Fuel Gas Code,ANSIZ223.1/NFPA54.

• Whererequiredbytheauthorityhavingjurisdiction,thisinstallationmustconformtotheStandard for Controls and

Safety Devices for Automatically Fired Boilers(ANSI/ASMECSD-1).

2) Makesurethataproperlysizedchimneyisavailablewhichisingoodcondition.Consulttheauthorityhaving

jurisdiction,PartVIofthismanual,andtheNational Fuel Gas Codeforadditionalinformationonventingrequirements.

3) Makesurethattheboileriscorrectlysized.UseanindustryacceptedsizingmethodsuchastheI=B=R Installation

Guide for Residential Hydronic Heating Systems (Pub. #200) and I=B=R Heat Loss Calculation Guide(Pub.#H21or

#H22).

4)  Makesurethattheboilerreceivedisconguredfornaturalgas.

5) GasConversionKitsarelistedbelow:

FORCESTM03 FORCESTM04 FORCESTM05 FORCESTM06 FORCESTM07 FORCESTM09

Natural to LP

(Propane)

106567-01 106567-02 106567-02 106567-03 106567-04 106567-04

LP (Propane) to

Natural

106568-01 106568-02 106568-02 106568-03 106568-04 106568-04

Warning

This Product Must be Installed By A Licensed Plumber Or Gas Fitter

when Installed Within The Commonwealth Of Massachusetts

IV. Locating the Boiler

1) Clearances:

• Observetheminimumclearancesshownbelow.Theseclearancesapplytoallcombustibleconstruction,aswellas

noncombustiblewalls,ceilingsanddoors.AlsoseeFigure2.

Front–18”  

RightSide–18” 

LeftSide–6” 

Rear–6”  

Top–17”

• A24”serviceclearancefromthejacketisrecommendedontheleft,right,andfrontoftheboiler.Theseclearances

maybereducedtothoseshowninFigure2,howeverservicingtheboilerwillbecomeincreasinglydifcultasthese

serviceclearancesarereduced.

• Iftherightside24”serviceclearanceisreduced,adequateclearancemustbemaintainedtoeasilyreadandaccessthe

controls.Alternatively,accessmaybeprovidedusingadoor

2) Thisboilermaybeinstalleddirectlyoveranon-carpetedcombustibleoor.

I. Pre-Installation

106324-04 - 4/18

3) Theboilermustbeinstalledonahardlevelsurface.

4)  Donotinstallthisboilerinalocationwheregasolineorotherammablevaporsorliquidswillbestoredorused.Donot

installthisboilerinanareawherelargeamountsofairbornedustwillbepresent,suchasaworkshop.

5) Theboilershouldbelocatedasclosetothechimneyaspossible.

6) Donotinstallthisboilerdirectlyonasurfacethatmaygetwet.Raisetheboileronapad.

FIGURE 2: FORCESTM BOILERS - CLEARANCES TO ALL TYPES OF COMBUSTIBLE CONSTRUCTION

AND NONCOMBUSTIBLE CEILINGS, WALLS, AND DOORS.

V. Air for Combustion & Ventilation

IV. Locating the Boiler

(continued)

Sufcientfreshairmustbesuppliedforcombustion,ventilationanduegasdilution.Provisionsforcombustion,ventilationand

uegasdilutionairforgasutilizationequipmentventedbynaturaldraftmustbemadeinaccordancewithlocalbuildingcodesor,

inabsenceofsuchcodes,inaccordancewith“AirforCombustionandVentilation”oftheNational Fuel Gas Code,ANSIZ223.1/

NFPA54.

106324-04 - 4/18

VI. Venting

Ventinstallationmustbeinaccordancewithlocalbuildingcodes,orthelocalauthorityhavingjurisdiction,ortheNational Fuel

Gas Code,ANSIZ223.1/NFPA54.

1. AtypicalventinstallationisillustratedbyFigure3.Thecomponentsofventinstallationaretheventdamper(ifused),

ventconnectorandchimney.

2. Installventdamper(seeFigure4)asfollows:

a) Openventdampercartonandremoveinstallationinstructions.Readtheinstructionsthoroughlybeforeproceeding.

Verifythatventdamperissamesizeasdraftdiverteroutlet.SeeFigure1.Unpackventdampercarefully.Do not

force closed damper blade. Forcingventdamperclosedmayresultindamagedgeartrainandvoidwarranty.

b) Ventdamperisfactoryshippedhavingapproximately¾”diameterholeintheventdamperblade,whichmust be left

openforboilersequippedwithstandingpilot,andshouldbepluggedonboilerswithanintermittentpilotsystem,

usingtheplugsuppliedwiththedamper.

Mounttheventdamperontheuecollarwithoutmodicationtoeitherandsecurewithsheetmetalscrews.Make

surescrewsdonotinterferewithdamperbladeoperation.Ventdamperbladepositionindicatormustbevisibleto

users.

c) Thedamperwireharnessisshippedwiredintotheboilerjunctionbox.Plugthelooseendofthisharnessintothe

damperandsecuretheexibleconduittothedamperusingaconnectornutprovided.

d) Installventconnectorpipeandventttingsfromventdamperoutlettochimneyorgasvent.Securewithsheetmetal

screwsandsupportasrequired.

3. GasVentTermination

 Gasventslocatednotlessthan8ft.(24m)fromaverticalwallorsimilarobstructionshallterminateabovetheroofin

accordancewithFigure5andTable2.

FIGURE 3: FORCESTM BOILER TYPICAL VENT SYSTEM INSTALLATION AND COMPONENTS

106324-04 - 4/18

FIGURE 4: VENT DAMPER INSTALLATION DETAILS

VI. Venting (continued)

Listed

cap

Listed

gas vent

H (minimum) -

Minimum height from roof

to lowest discharge opening

Roof pitch is x/12

Lowest discharge opening

FIGURE 5: TERMINATION LOCATIONS FOR GAS VENTS

WITH LISTED CAPS AT LEAST 8 FT (2.4 M)

FROM A VERTICAL WALL:

Roof Slope H (minimum)

ft m

Flat to 6/12 1.0 0.30

Over 6/12 to 7/12 1.25 0.38

Over 7/12 to 8/12 1.5 0.46

Over 8/12 to 9/12 2.0 0.61

Over 9/12 to 10/12 2.5 0.76

Over 10/12 to 11/12 3.25 0.99

Over 11/12 to 12/12 4.0 1.22

Over 12/12 to 14/12 5.0 1.52

Over 14/12 to 16/12 6.0 1.83

Over 16/12 to 18/12 7.0 2.13

Over 18/12 to 20/12 7.5 2.27

Over 20/12 to 21/12 8.0 2.44

TABLE 2: ROOF SLOPE HEIGHTS

106324-04 - 4/18

FIGURE 6: GAS CONNECTION TO BOILER

VII. Gas Piping

*StateofMassachusettsRequiresManual

Shut-offValvetobe“T”HandleType

Gaspipingtotheboilermustbesizedtodeliveradequategasfortheboilertoreatthenameplateinputatalinepressure

betweentheminimumandmaximumvaluesshownontheratingplate.Formoreinformationongaslinesizing,consultthe

utilityorChapter2oftheNational Fuel Gas Code.

 Figure6showstypicalgaspipingconnectiontotheFORCESTMboiler.Asedimenttrapmustbeinstalledupstreamof

allgascontrols.Installamanualshut-offvalveoutsidethejacketandgroundjointunionasshown.

 Theboileranditsgasconnectionmustbeleaktestedbeforeplacingtheboilerinoperation.Whendoingthis,theboiler

anditsindividualshut-offmustbedisconnectedfromtherestofthesystemduringanypressuretestingofthatsystemat

pressuresinexcessof1/2psi.Whenpressuretestingthegassystematpressuresof1/2psiorless,isolatetheboilerfromthe

gassupplysystembyclosingitsindividualmanualshut-offvalve.

106324-04 - 4/18

CAUTION

• INSTALLBOILERSOTHATTHEGASIGNITIONSYSTEMCOMPONENTSAREPROTECTED

 FROMWATER(DRIPPING,SPRAYING,RAIN,ETC.)DURINGAPPLIANCEOPERATIONANDSERVICE

 (CIRCULATORREPLACEMENT,ETC.).

• OPERATIONOFTHISBOILERINASYSTEMHAVINGSIGNIFICANTAMOUNTSOFDISSOLVED

 OXYGENCANCAUSESEVEREHEATEXCHANGERCORROSIONDAMAGE.

VIII. System Piping

General Piping Notes

Figure7showsrecommendednearboilerpipingformostcommontypesofgravityreturnsteamsystems.Additional

informationonsteamsystemdesignmaybefoundinInstallation Guide for Residential Hydronic Heating Systems(Pub.

#200).

Oneoftheprimarypurposesofthisnearboilerpipingistoseparatetinywaterdropletsfromthesteamexitingtheboiler

sothat“dry”steamissenttothesystem.Ifthenearboilerpipingisnotcorrect,wetsteamwillenterthesystemandthe

followingproblemsmayoccur:

• Short cycling on low water

• BoilerorsystemFlooding

• Hammering

• Failuretoheatoneormoreradiators

AvoidthethreecommonpipingmistakesshowninFigure8.Thisapplieseveniftheexistingboilerhasoneofthepiping

mistakesshowninFigure8andappearstobeworking.Iftwoormoresteammainsmustbeconnectedtotheboiler,connecta

separatetake-offforeachmainintotheheaderbetweentheriser(s)andequalizer.Alsonotethefollowingpoints:

1) Asizereductionmustbemadetoconnecttheheadertotheequalizer.Thisreductionmustbemadeintheequalizerline.

Donotmakethissizereductioninthehorizontalheader.

2) Onepipesteamsystemsrequireairventsoneachradiator,aswellasattheendofeachmain.Forthesystemtowork

properly,theseventsmustbeproperlyinstalled,sized,andbeingoodcondition.Inspectandreplaceanydefectivevents.

Iftherearenoventsattheendsofthemains,installthem.

3) DonotattempttomanifoldmultipleFORCESTMboilerswithgravityreturns.

4) Forinstallationswithcondensateorboilerfeedpumps,followthepumpmanufacturer’spipinginstructions.Such

systemsgenerallydonotrequireHartfordloops.

5) Donotuseacheckvalveinplaceof,orinadditionto,aHartfordlooponagravityreturnsystem.

6) Pipethellconnectionfromacleansourceofcoldwater.Whenthewatersupplyisfromawell,makesurethatastrainer

isinstalledinthewellsystem.

7) PipingwithaChiller-Iftheboilerisusedinconjunctionwithachiller,pipetheboilerinparallelwithchiller.Use

isolationvalvestopreventchilledwaterfromenteringtheboiler.

106324-04 - 4/18

Piping Installation

1) Removepartsbagfromboilercrate.

2) Installsafetyvalve(spindlemustbeinverticalposition)intotappingonboilerleftside(seeFigure1)usingthe3/4”NPT

nippleandelbowsupplied.

3) Pipethedischargeofthesafetyreliefvalvetoalocationwherewaterorsteamwillnotcreateahazardorcauseproperty

damageifthevalveopens.Theendofthedischargepipemustterminateinanunthreadedpipe.Ifthesafetyvalve

dischargeisnotpipedtoadrainitmustterminateatleast6inchesabovetheoor.Theterminationofthesafetyvalve

dischargepipingmustbeinanareawhereitisnotlikelytobecomepluggedbydebrisorsubjectedtofreezing.

4) Installdrainvalveintotappingonboilerleftsideusingthe2x3/4bushingprovided(seeFigure1).

5) Connectsystemsupplyandreturntoboiler.SeeFigure7.FORCESTM03throughFORCESTM06maybepipedwith

oneortworisers.Install2”pluginTappingGifoptionalsecondsupplyAisnotused.Twosupplyrisersarerequiredon

theFORCESTM07andFORCESTM08.

6) PipingwithaChiller-Iftheboilerisusedinconjunctionwithachiller,pipetheboilerinparallelwithchiller.Use

isolationvalvestopreventchilledwaterfromenteringtheboiler.

DANGER

•

PIPESAFETYVALVEDISCHARGETOASAFELOCATION.

• DONOTINSTALLAVALVEINTHESAFETYVALVEDISCHARGELINE.

• DONOTMOVESAFETYVALVEFROMFACTORYLOCATION.

• DONOTPLUGSAFETYVALVEDISCHARGE.

• DONOTINSTALLASAFETYVALVEWITHASETTINGGREATERTHAN15PSI.

VIII. System Piping (continued)

106324-04 - 4/18

FORCESTM03 /

FORCESTM04 /

FORCESTM05 /

FORCESTM06

FORCESTM07 /

FORCESTM08

2** 2

2 3

1½ 1½

1¼ ¼

** Optional

FIGURE 8: COMMON NEAR-BOILER PIPING MISTAKES

FIGURE 7: STEAM BOILER PIPING FOR GRAVITY RETURN

MINIMUM PIPE SIZE

VIII. System Piping (continued)

106324-04 - 4/18

AllFORCESTMseriesboilersareequippedwithtappingstopermittheconnectionofaLinkSL™IndirectWater

Heater,orotherindirectwaterheater.Inthistypeofsystem,hotboilerwaterisdrawnfrombelowthewaterlineand

passedthroughtheheatexchangerintheindirectwaterheater.Thissectiondescribesboiler-sidepipingonly.RefertoLink

SL™Installation,OperatingandServiceInstructionsforadditionalinformation

.Thecomponentsinthissystemandtheir

functionsareasfollows:

1) Circulator-MountthecirculatorasshowninFigure9.Thecirculatorshouldbelocatedaslowandasclosetothe

boileraspractical.Donotinstallvalves,orotherdeviceshavingasignicantpressuredrop,betweentheboiler

andthecirculatorinlet.Allpipingbetweentheboilerandthecirculatorinletshouldbe1”,regardlessofthesizeof

thepipingrequiredintherestofthesystem.SeeFigure10inPartXforwiringinformation.

2) “Y”Strainer-Installa“Y”strainertopreventsedimentfromaccumulatinginsidetheindirectwaterheater.

3) CheckValve-Preventsgravitycirculationthroughtheindirectwaterheaterwhentheboilerisrespondingtoacall

forheat.

4) BoilerLimitControl-UseaSPSTbreak-on-risetemperaturelimitcontrolsuchastheHoneywellL4006A.Donot

setthelimitabove180°Fasdoingsomaycausetheboilertosteamwhenthereisnocallforheat.SeeFigure10

forwiringinformation.

5) ValvesandUnions-Installshut-offvalves,drainvalves,andunionsinlocationsthatwillfacilitatemaintenanceof

thesystem.Donotinstallanyvalvesbetweentheboilerandcirculatorinlet.

IMPORTANT

•  Someindirectwaterheatersmaynotbesuitableforusewithasteamboiler.Consultthewaterheater 

manufacturer’sguidelinesbeforeinstallingitinthistypeofsystem.

•  Boilerwatertemperaturesandowratesinthistypeofsystemmaybeconsiderablylowerthanthoseupon

whichthewaterheatermanufacturer’sratingsarebased.Thismayresultinsubstantiallylongerwaterheater

recoverytimes.

FIGURE 9: INDIRECT WATER HEATER BOILER-SIDE PIPING

IX. Indirect Water Heater Piping

106324-04 - 4/18

1) 120VoltWiring-Theboilershouldbeprovidedwithitsown15Abranchcircuitwithfuseddisconnect.All120volt

connectionsaremadeinsidethejunctionboxontheleftsideoftheboiler.Removethetransformertogainaccesstothis

box(alsoseeFigures11and12):

• Hot(“black”)-Wirenuttoblacktransformerlead

• Neutral(“white”)-Wirenuttowhitetransformerlead

• Ground(“green”orbare)-Groundscrewinsidejunctionbox.

2)ThermostatWiring-Followthermostatmanufacturerinstructions.Toinsureproperthermostatoperation,avoid

installationinareasofpooraircirculation,hotspots(nearanyheatsourceorindirectsunlight),coldspots(outside

walls,wallsadjacenttounheatedareas,locationssubjecttodrafts).ProvideClassIIcircuitbetweenthermostatand

boiler.Connectthermostatwireleadstothebluetransformerleadandbrownrelayleadinsidethejunctionbox.Setthe

heatanticipatorto0.2A.

WARNING

Allwiringandgroundingmustbedoneinaccordancewiththeauthorityhavingjurisdictionor,intheabsenceofsuch

requirements,withtheNationalElectricalCode(ANSI/NFPA70)

X. Electrical

106324-04 - 4/18

FIGURE 10: WIRING INDIRECT WATER HEATER TO BOILER

Indirect Water Heater Wiring

Figure10showseldwiringforanindirectwaterheater.AHoneywellR845AorequivalentDPSTrelayandtransformer

isrequired.ThehighlimitdescribedinPartIXmustalsobesuppliedbytheinstaller.Acallforheatfromtheindirectwater

heaterthermostatwillenergizetherelaymakingbothsetsofcontacts.Onesetofthesecontactsthenenergizesthecirculator.

Theothersetofcontactswillmakethe“T”and“T”contactsontheburnerprimarycontrol,ringtheburner.Iftheboiler

watertemperatureexceedsthehighlimitsettingof180°F,thehighlimitwillopenthe“T”-“T”circuitandtheburnerwill

shutdown.

Ifthereisacallforspaceheat,theheatingthermostatwillmakethe“T”-“T”circuitandtheboilerwillrewithoutregard

tothestatusoftheindirectwaterheater.Thelowwatercut-offandpressurelimitcontrolwillinterrupt120voltpowertothe

burnerintheeventofalowwaterorexcessivepressurecondition.

X. Electrical (continued)

106324-04 - 4/18

FORCESTM Control System – Sequence of Operation

(RefertoFigures11&12forladderandconnectiondiagrams)

Sequence of Operation, Intermittent Ignition

1)Whentheboilerisenergized,24voltsisimmediatelyappliedtoterminals“1”(blue)and“4”(yellow)onthevent

damper.Assumingthatthereisnocallforheat,andthatthedamperswitchisinthe“automatic”position,thedamper

willclose.OnboilersequippedwithHydrolevelCG400Aprobetypelowwatercut-offs,voltageisalsoalwaysapplied

toterminals“1”(blue)and“2”(yellow)onthelowwatercut-offtopowerthewaterlevelsensingcircuit.

2)Assumingthatwaterisabovethecut-offlevel,powerwillappearatterminal“3”ontheCG400ALWCO.

3)Assumingthatsteampressureisbelowthepressurelimitsetting,powerwillappearononesideofrelaycontact1R1

(Graylead).Relay1RistheR8225mountedunderthejunctionbox.

4)  Acallforheatfromthethermostatenergizesrelaycoil1Rcausingcontacts1R1tomake.Currentthenowsthrough

contacts1R1topinterminal“2”(orange)attheventdamperandthedamperopens.

5)  Oncetheventdamperisfullyopen,anendswitchinsidethedamperwillmake,energizingpin“3”(red)atthedamper.

6)  Currentpassesfromterminal“3”ontheventdamperthoughtheamerolloutandblockedvent(“spill”)switches.Under

normalconditions,bothoftheseswitchesaremadeandvoltagewillthereforeimmediatelyappearacrossterminals

“24V”and“24V(GND)”ontheignitionmodule.

7)  Uponapplicationofvoltageacrossthe“24V”and“24V(GND)”terminals,theignitionmodulewillstartanignition

sparkatthepilotandapply24voltsacrossthepilotvalve(terminals“PV”and“MV/PV”).

8)  Oncethepilotisestablished,thepilotamewillactasadiode,convertingtheACcurrentattheelectrodetoahalfwave

DCcurrentatthepilot’sgroundstrap.ThisDCcurrentowsthroughtheboilertothe“GND(BURNER)”connectionon

theignitionmodule.Fortheignitionmoduletorecognizethatapilotameispresent,theDCcurrentowingintothis

terminalmustbeinexcessofapproximately1.0uA.

9)  Oncetheignitionmoduledetectsthepresenceofapilotame,voltageisappliedacrossthemainvalve(terminals“MV”

and“MV/PV”),openingthevalveandestablishingmainame.

10) Formoreinformationonmoduleoperation,consulttheignitionmoduleinstructionssuppliedwiththeboilerorthelocal

Fergusonrepresentative.

Safety Control Operation - Intermittent Ignition

HydrolevelCG400ALowWaterCut-off-Interruptsburneroperationifthewaterintheboilerdropsbelowasafelevel.Asthe

waterdropspastthecut-offpoint,theamberlampontheCG400Awillglow.TheCG400Awillinterruptpowertotheburners

15secondsafterthewaterleveldropspastthecut-offpoint.Thisfeaturepreventsshortcyclingoftheburnersduetoabouncing

waterline.Theburnerswillthenremainoffuntil30secondsafterthewaterlevelhasbeenraisedabovethecut-offpoint.

 TheCG400Aisalsoequippedwithafeaturewhichwillshutdowntheburnersaftertheyhavebeenringfor10minutes,

regardlessofthewaterlevelstatus.TheCG400Athenkeepstheburnersofffor90seconds,allowingthewaterlevelandanyfoam

whichispresenttosettle.Duringthis90secondinterval,thegreenLEDontheCG400Awillglow.Ifthewaterlevelisstillabove

thecut-offlineattheendofthis90secondinterval,theCG400Awillrestarttheburners.

 Theventdamperwillclosewhenthelowwatercut-offinterruptsburneroperation.

PressureLimitControl-Interruptsburneroperationwhenthepressureintheboilerexceedsthe“Cut-in”settingplusthe

differentialsetting.The“Cut-in”settingisshownontheoutsideofthecontrolandisadjustedusingthescrewonthetopofthe

control.Thedifferentialisadjustedusingthewhitethumbwheelontheinsideofthecontrol.Burneroperationisrestoredwhen

thepressureintheboilerdropstothe“Cut-in”pressure.

 Theventdamperwillclosewhenthepressurelimitcontrolinterruptsburneroperation.

BlockedVentSwitch(BVS)-Automaticallyinterruptsburneroperationintheeventthatuegasspillsfromthedraftdiverter

opening.Thisswitchisequippedwitharesetbuttonwhichmustbepressedtorestorenormalburneroperation.Anopenblocked

ventswitchisindicativeofaproblemwiththeventsystem.Iftheblockedventswitchopens,thecauseoftheventingproblem

mustbefoundandcorrectedbyaqualiedgasservicetechnicianbeforetheblockedventswitchisreset.

FlameRolloutSwitch(FRS)-Automaticallyinterruptsburneroperationwhenamesorexcessiveheatarepresentinvestibule.

Theamerolloutswitchisasingleusedevicewhichmustbereplacedbyanidenticalswitchinordertorestorenormaloperation.

Anopenamerolloutswitchisusuallyindicativeofapluggedheatexchanger.Thecauseoftheamerolloutmustbefound

andcorrectedbyaqualiedgasservicetechnician,andtheswitchreplacedwithanidenticalone,beforetheboilerisreturnedto

operation.

X. Electrical (continued)

106324-04 - 4/18

FIGURE 11: WIRING DIAGRAM, HYDROLEVEL CG400A LOW WATER CUTOFF

X. Electrical (continued)

106324-04 - 4/18

FIGURE 12: LADDER DIAGRAM, HYDROLEVEL CG400A LOW WATER CUTOFF

X. Electrical (continued)

106324-04 - 4/18

Usethefollowingprocedureforinitialstart-upoftheboiler:

1)  Makesurethattheboilerislledwithwatertothenormalwaterline(283/4inchesabovetheoororpadonwhichthe

boilerisinstalled)

2) Checkallnewgaspipingforleaksandpurgepipingsectionsthatarelledwithair.SeePart4oftheNational Fuel Gas

Codeforadditionalinformationontestingandpurginggaslines.

3) Verifythatventsystemiscompleteandfreeofobstructionsbeforeattemptingtoreboiler.

4) Inspectallwiringforlooseoruninsulatedconnections.

5) Makesurethemainburnersareseatedproperlyintherearofburnertrayandonorices.

6) Adjuststeampressurelimitcontrolforacut-inpressureof0.5psiandadifferentialpressureof1psi.

7) Adjustthermostattothehighestsetting.

8) StarttheboilerusingtheOperatingInstructions.SeeFigure14.

9) Uponinitialstart-up,thegastrainwillbelledwithair.Evenifthegaslinehasbeencompletelypurgedofair,it

maytakeseveraltriesforignitionbeforeaameisestablished.Onceaamehasbeenestablishedforthersttime,

subsequentcallsforburneroperationshouldresultinaameonthersttry.

10) Observepilotburnerame.Pilotburnerproducesthreeames.Thecenteroneshouldbeasteadymediumblueame

coveringaround3/8”to½”ofsparkelectrode/amerod.SeeFigure13.

12) Makesureventdamperisinopenpositionwhenmainburnersarering.

13) Inspectthemainburneramesvisiblethroughtheobservationportinburneraccesspanel.Theameshouldbestable

andmostlyblue(seeFigure15).Noyellowtippingshouldbepresent;however,intermittentecksofyellowandorange

intheamearenormal.

14) Checkentiregastrainforleaksusingsoapandwaterorotherapprovedleakdetectionmethodwhileboilerisring.Fix

anyleaksfoundimmediately.

15) Rungasvalvesafetyshutdowntest.Withmainburnersring,disconnectignitioncablefromignitionmodule.Both

pilotburnerandmainburnersshouldstopring.

WARNING

•

NEVERUSEAFLAMETOCHECKFORGASLEAKS.

• MAKESURETHATTHEAREAAROUNDTHEBOILERISCLEARANDFREEFROM

COMBUSTIBLEMATERIALS,GASOLINE,ANDOTHERFLAMMABLEVAPORSANDLIQUIDS.

• DAMPERMUSTBEINOPENPOSITIONWHENAPPLIANCEMAINBURNERISOPERATING.

XI. System Start-up

Page is loading ...

PROSELECT Force Boilers FORCESTEAM07NH Installation guide

Brand: PROSELECT Force Boilers

Model: FORCESTEAM07NH

Type: Installation guide

Download PDF

report

PROSELECT Force Boilers FORCESTEAM07NH Installation guide

PROSELECT Force Boilers FORCESTEAM07NH Installation guide

Related papers

Other documents