FULTON Caliber, Caliber 300, Caliber 500, Caliber 750, Caliber 850 Installation And Operation Manual

INSTALLATION AND

OPERATION MANUAL

Caliber

High E ciency Hydronic Boilers

300,000 - 850,000 BTU/HR

Serial/ National Board Number

Model

Fulton Order

Sold To

Job Name

Date

CAL-IOM-2012-1220

CAL-IOM-2012-1220 TABLE OF CONTENTS

Introduction 1-1

Overview .............................................................................................................. 1-2

Warnings & Cautions ............................................................................................1-2

Disclaimers and Local Codes ................................................................................1-2

Installation 2-1

Product Overview ................................................................................................. 2-2

Placement & Rigging ........................................................................................... 2-3

Clearances and Serviceability ..............................................................................2-3

Install Boiler Trim .................................................................................................2-5

Install Water Piping .............................................................................................. 2-6

LOW WATER CUT OFF ...................................................................................................................27

Meet Water Chemistry Requirements ................................................................2-10

PREVENT FREEZING ...................................................................................................................211

PREVENT OXYGEN CONTAMINATION ........................................................................................211

ELIMINATE SYSTEM AIR ............................................................................................................211

Fill the Boiler With Water ...................................................................................2-12

Install Gas Piping ............................................................................................... 2-13

Venting ............................................................................................................... 2-14

COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................215

COMBUSTION AIR PIPED FROM OUTSIDE BUILDING WITHOUT SEALED COMBUSTION ........215

AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................215

Exhaust Venting .................................................................................................2-16

STANDARD VENTING CONFIGURATION, CATEGORY IV .............................................................216

SIZING AIR INTAKE AND EXHAUST PIPING ...............................................................................217

COMMON AIR INTAKE AND EXHAUST VENTING OF MULTIPLE BOILERS .................................218

INTAKE DUCT SIZING .................................................................................................................218

Condensate Drain Piping ....................................................................................2-18

Venting Terminations ......................................................................................... 2-19

WALL THIMBLE INSTALLATION .................................................................................................220

HORIZONTAL VENT TERMINATION ............................................................................................221

Electrical Connections ....................................................................................... 2-22

Normal Operation of the Boiler ............................................................................ 3-4

CHANGING THE OPERATING SET POINT .....................................................................................35

SETTING COMBUSTION ................................................................................................................36

Shut Down Procedures .........................................................................................3-7

NORMAL SHUT OFF PROCEDURES .............................................................................................37

EMERGENCY SHUT OFF PROCEDURES .......................................................................................37

SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ........................................37

STARTING BOILER AFTER PROLONGED SHUTDOWN ..................................................................37

SOLA Control Features .......................................................................................... 3-8

VIEWING THE FLAME SIGNAL ....................................................................................................38

CYCLE AND RUN HOURS MONITORING .......................................................................................38

BOILER NAMING ..........................................................................................................................38

DELTA T LIMIT ...............................................................................................................................39

STACK LIMIT .................................................................................................................................39

LEAD/LAG CONFIGURATION .......................................................................................................39

MODBUS CONFIGURATION .......................................................................................................310

Maintenance 4-1

General ................................................................................................................. 4-2

Daily Maintenance and Inspection Schedule ......................................................4-2

Weekly Maintenance and Inspection Schedule .................................................. 4-2

Monthly Maintenance and Inspection Schedule .................................................4-2

Procedure for Cleaning the Air Inlet Filter ..........................................................4-3

Relief Valve Testing ............................................................................................... 4-3

Annual Maintenance and Inspection Schedule ................................................... 4-3

EXAMINE THE VENTING SYSTEM ................................................................................................44

INSPECT HEATING SYSTEM FOR OTHER PROBLEMS ..................................................................44

Procedure for Removing/Cleaning The Burner .................................................... 4-4

Procedure for Cleaning Heat Exchanger ...............................................................4-5

After All Repairs and Maintenance ...................................................................... 4-6

Troubleshooting ...................................................................................................4-6

Warranty & Parts 5-1

Operation 3-1

Perform Pre-Start-Up Inspection .........................................................................3-2

Fill and Purge the System..................................................................................... 3-2

SOLA Control Program Presets .............................................................................3-2

Commission The Boiler ......................................................................................... 3-2

Test of Ignition Safety System .............................................................................. 3-3

Perform Test of Low Water Cut O ....................................................................... 3-3

Perform Test of Limit Controls ............................................................................. 3-3

Perform Test of Low Gas Pressure Switch ............................................................ 3-4

Perform Test of High Gas Pressure Switch ............................................................ 3-4

Perform Test of Air Switch .................................................................................... 3-4

Test of High Back Pressure Switch ........................................................................3-4

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

Parts ..................................................................................................................... 5-2

Standard Warranty for Fulton Caliber Hydronic Boilers ....................................... 5-3

0-1

TABLE OF CONTENTS CAL-IOM-2012-1220

0-2

INTRODUCTION

INSTALLATION

1

2

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

1-1

INTRODUCTION CAL-IOM-2012-0518 SECTION 1

Overview

Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:

§ Material inspections

§ Manufacturing process inspections

§ Electrical components inspection

§ Operating test

§ Final engineering inspection

§ Crating inspection

§ Piping leak test

This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, quali ed installers and service personnel. Trained personnel are responsible

for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are quali ed and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training speci c to this product.

When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jurisdictional authorities prior to installation.

Warnings & Cautions

WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS.

§ WARNINGS must be observed to prevent serious injury

or death to personnel.

§ CAUTIONS must be observed to prevent damage

or destruction of equipment or loss of operating e ectiveness.

All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.

Disclaimers and Local Codes

Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, in the US to the National Fuel Gas Code ANSI Z223.1/NFPA 54 latest edition, and the speci c instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.

When required by local codes, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for a maximum allowable working pressure and operating temperature of 160 psig and 210 F (121 C) respectively.

1-2

INSTALLATION

INTRODUCTION

INSTALLATION

1

2

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-1

INSTALLATION CAL-IOM-2012-1220 SECTION 2

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Operation of this boiler beyond its design limits or with unapproved modi cations may result in injury and/or equipment damage.

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines o ered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

Product Overview

Prior to the performance of installation, operation, or maintenance procedures, personnel should become familiar with the equipment (Table 1 and Figure 1) and its components.

The Fulton Caliber hydronic boiler is an automatic, fuel- red, high-e ciency boiler. The boiler can either be of the sealed combustion/direct vent type or utilize conventional combustion air intake and  ue methods.

The boiler is capable of sidewall venting when the appropriate venting materials are used, and when permitted by local code requirements. It features low emission pre-mix combustion with pulse width modulation and fully automatic safety controls.

The Fulton Caliber boiler is constructed to ASME Section IV and certi ed by the Edison Testing Lab (ETL) to Underwriters Laboratories (UL) 795 Issue 2006/10/27 Edition 6 Standard for Safety Commercial-Industrial Gas Heating Equipment. All Caliber boilers are hydrostatically tested, test  red and shipped as a complete packaged unit. Fuel, water, and electrical connections are similar to other boilers of this type.

This boiler is to be installed as part of a hydronic heating system. A quali ed engineer must be consulted for the selection of the equipment and components of the heating system. Various system conditions can result in incorrect heat distribution to users of the heating system.

Each Caliber Boiler is supplied with the following:

§ Lightweight casing utilizing an air gap as insulation

§ Integrated combustion supervision and temperature operating control

4 CAUTION

This boiler is certi ed for indoor installation only.

This boiler is not designed for use in systems where water is continuously replenished. The warranty is valid for closed loop systems only.

Fulton cannot be held responsible for the selection, engineering, installation, or sizing of any additional equipment or components of the hydronic heating system.

A quali ed engineer must be consulted for equipment selection and heating system components.

§ Operating and high temperature dual temperature probe

§ Low water  ow switch

§ Fully matched modulating premix combustion system including burner,

blower and fuel train controls.

§ ASME pressure relief valve

§ Instruction manual

§ Wiring diagram

§ Combustion Air Adapter

§ Temperature and pressure (T&P) gauge

§ Manual Air Vent

The customer should examine the equipment for any damage. It is the responsibility of the installer to ensure all parts supplied with the equipment are  tted in a correct and safe manner.

2-2

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

Placement & Rigging

Proper placement of your Fulton product is essential. Attention paid to the following points will save a great deal of di culty in the future. Correct placement is the  rst step to trouble-free installation, operation, and maintenance.

Adhere to the following for placement and rigging:

1. Check building speci cations for permissible  oor loading. Use Table 1 for unit reference.

2. Conform to all the requirements of all national, state and local codes established by the authorities having jurisdiction and/or the U.S. to the National Fuel Gas Code, latest edition. Authorities having jurisdiction should be consulted before installations are made. Where required by local codes, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

3. Since an external electrical source is utilized, the boiler, when installed, must be electrically ground in accordance with the National Electric Code, American National Standards Institute (ANSI) National Fire Protection Association (NFPA) 70, latest edition.

4. This boiler is certi ed for indoor installation only. National Electrical Manufacturers Association (NEMA) 3R Con guration is available as an option from the factory, but an existing boiler cannot be retro tted for outdoor installation.

5. Install so that all system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service.

6. Install on a level, non-combustible surface in the vertical position. Concrete is strongly recommended.

7. Provide combustion and ventilation air in accordance with applicable provisions of local building codes or: USA – NFPA 54/ANSI Z223.1, Section

5.3, Air for Combustion and Ventilation.

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations.

Competent personnel in accordance with all applicable local codes should carry out the installation of the Fulton equipment. All state and jurisdictional codes beyond the scope of the applicable ASME Boiler and Pressure Vessel Codes, for its corresponding classi cation, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation.

A competent rigger experienced in handling heavy equipment should handle rigging your equipment into position.

The equipment must be installed on a non-combustible surface.

Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions exist.

Failure to provide proper minimum clearances between equipment and combustible materials may result in  re.

8. Locate the boiler so that the air supply and exhaust piping between the boiler and outside wall/roof are within the maximum lengths for horizontal or vertical venting if sealed combustion will be used. See Clearances and Serviceability section of this manual.

Clearances and Serviceability

Adhere to the following for clearances and serviceability:

1. All local and national codes (NFPA, ANSI, UL, CSA, ASME) must be followed for proper clearances and serviceability for your boiler or heater. Authorities having jurisdiction should be consulted before installations are made.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4 CAUTION

Do not allow weight to bear on equipment components to prevent damage.

Boiler must be installed in such a way as to protect from water (including dripping,

misting, etc.) during boiler operation.

2-3

INSTALLATION CAL-IOM-2012-1220 SECTION 2

TABLE 1  OPERATING REQUIREMENTS

Caliber Model Size

Input (BTU/Hr)

300 500 750 850

300,000 500,000 750,000 850,000

Output (BTU/Hr)

Natural Gas Consumption (ft3/hr)

Propane Consumption (ft3/hr)

Gas Supply Pressure Minimum Maximum

Dry Weight LB KG

Operating Weight LB KG

Control Voltage (V/Hz/Ph)

Blower Voltage (V/Hz/Ph)

Gas Connection IN

MM

Water Inlet/Outlet Connection IN

MM

Flue Connection IN

283,500 472,500 708,750 803,250

297 495 743 842

120 200 300 340

4.0

14

500 570 680 690

227 259 308 313

520 605 720 740

236 274 327 336

1 1 1 1

25.4 25.4 25.4 25.4

1.25 1.5 2 2

31.75 38.1 50.8 50.8

4 4 6 6

4.0

14

120/60/1

4.0

14

4.0

14

MM

Air Intake Connection IN

MM

Boiler Width IN

MM

Boiler Height IN

MM

Boiler Depth (Cabinet) IN

MM

Amp Draw

Notes:

Speci cations and dimensions are approximate. We reserve the right to change speci cations and dimensions without notice.

*The use of propane is allowable with concentration of up to 5% propylene, commonly referred to as HD5. The use of o -standard grades of propane,

such as propane HD10 (10% propylene) is not permitted unless a system is in place to reduce propylene concentration to less than 5% prior to

reaching any fuel delivery piping. This is the responsibility of the customer. Verify propylene concentration with supplier prior to commissioning and

operation of equipment.

101.6 101.6 152.4 152.4

4 4 4 4

101.6 101.6 101.6 101.6

28 28 28 28

711.2 711.2 711.2 711.2

51 51 51 51

1295.4 1295.4 1295.4 1295.4

31.25 44 57.25 57.25

793.75 1117.6 1454.15 1454.15

1.8 3.6 3.6 3.6

2-4

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

36”

SAFETY RELIEF VALVE

4”

AIR INLET

36”

2. Appropriate front, back, side and top clearances must be maintained (Figure 1). This will allow access around the equipment to facilitate maintenance and a safe work environment. A four inch (101.6 mm) side clearance is acceptable between boilers.

3. Ensure all labels on the boiler will be fully visible for maintenance and inspection.

Install Boiler Trim

Each Caliber boiler is supplied with a safety relief valve sized in accordance with ASME requirements. The safety relief valve comes pre-piped into the water outlet manifold.

Adhere to the following installation requirements:

1. The safety relief valve (Figure 1) must:

» Be connected to the coupling located in the

top rear outlet section of the boiler.

» Be installed in the vertical position.

» Be installed with a 4 inch (101.6 mm) nipple

between the boiler and the safety valve.

NOTE: ´ Safety relief valve size is determined by trim pressure

and is supplied in the trim kit along with appropriate bushing, inlet and outlet sizes.

The discharge of the safety relief valve is piped to the back of the boiler. The installer must complete the piping to a safe location. The discharge pipe must:

» Not have a diameter less than the full area of the

valve outlet.

» Be as short and straight as possible and so

arranged as to avoid undue stress on the valve.

» Be supported by means other than the safety

valve itself.

» Be piped to avoid danger of scalding personnel.

NOTE: ´ Each boiler is equipped with a pressure-temperature

gauge to be installed in the outlet piping section of the boiler.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

FIGURE 1 CALIBER HYDRONIC BOILER CLEARANCES

2-5

INSTALLATION CAL-IOM-2012-1220 SECTION 2

! WARNING

Ensure tank return line is not clogged. Obstructions in the line could cause damage to the pump seal.

The discharge from the safety relief valve must be arranged to ensure no danger to personnel or equipment damage. Provisions must be made to properly pipe the safety relief discharge away from the boiler to the point of discharge.

No shuto of any kind shall be placed between the safety relief valve and the boiler, or in the discharge pipe between the valve and the atmosphere. Doing so may cause an explosion from overpressure.

The hydronic system should never be  ushed while the boiler is attached to the system since the debris could accumulate in the boiler and block water from passing through the heat exchanger.

Install Water Piping

All water supplies contain some solids, dissolved gases or dissolved minerals. These may promote corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting boiler performance, valve operation and general pipe longevity, each location must be analyzed and treated accordingly.

Adhere to the following for water piping installation:

1. Boiler has a maximum temperature di erential across the heat exchanger

at high  re, and has a minimum  ow requirement. Use Table 2 to identify ideal  ow rates for the Caliber boiler.

TABLE 2  IDEAL FLOW RATES/GALLONS PER MINUTE*

Caliber Model 300 500 750 850

GPM at Operating Temperature of 20 F dT *

GPM at Operating Temperature of 60 F dT (max dT)

*typical

30 45 70 80

8.8 15.4 17.6 19.8

Ensure all labels on the boiler are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.

Do not store or use gasoline or other  ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

4 CAUTION

Low  ow conditions will cause excessive cycling, damage and failure of equipment.

Ensure water piping arrangements allow for heat-up times at or below 30 seconds; this will reduce condensation which may contribute to equipment failure.

Circulating pump power supply must be external to the boiler. The use of the SOLA as a power supply is prohibited. The pump contacts provided with the SOLA are for controlling the pump only.

2. Ensure piping arrangements allow for heat-up times at or below 30 seconds; this will reduce condensation which may contribute to equipment failure.

3. Pipe unions and isolation valves are recommended on both water connections for ease of service.

4. Install piping so that the boiler is not supporting any additional piping.

5. The top water connection on the back of the boiler is the hot water outlet and must be connected as the supply to the system. The bottom connection is the return/boiler inlet. See Figure 2.

6. Install a hot water circulator, remote mounted from boiler. Do not attach directly to the boiler. Refer to Figures 3 and 4 for proper location of circulators.

7. Install manual purging valves in all loops and zones. Install a pressure reducing (automatic  ll) valve in the cold water  ll line to the boiler system. Check that the proposed operation of zone valves, zone circulator(s) and diverting valves will not isolate air separator(s) and/ or expansion tank(s) from the boiler. Clearance from hot water pipes to combustibles must be at least 6 inches (152.4 mm).

8. The boiler, when used in conjunction with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. If the boilers are connected to heating coils, located in air handling units where they may be exposed to refrigerated air circulation, such boiler

2-6

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

piping systems shall be equipped with  ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

9. The boiler is not provided with a drain valve directly on the boiler. A drain valve should be installed near the system return (water inlet) connection to the boiler and piped to a drain.

10. Before installing a Caliber boiler into a hydronic loop, be sure that the system piping and any other components of the system are clean and free of debris and any foreign matter. The hydronic system is completely  ushed prior to installing the boiler itself. Install a strainer upstream of each boiler to ensure that no foreign matter will have the opportunity to get inside the heat exchanger.

Air Inlet

Water Outlet Connection (System Supply)

Water Inlet Connection (System Return)

Customer Electrical Connection

¡ Low Water Cut Oﬀ

The Caliber boiler comes with an installed  ow-switch type low water cut-o (LWCO). The LWCO does not require  eld piping or wiring. If the  ow switch does not sense  ow, the boiler will shut down and an alarm condition will be annunciated on the SOLA color screen display.

Exhaust Outlet Connection

FIGURE 2  CONNECTIONS

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-7

INSTALLATION CAL-IOM-2012-1220 SECTION 2

2-8

FIGURE 3 - SAMPLE PIPING LAYOUT: SINGLE BOILER WITH RETURN WATER TEMPERATURE >140 F (60 C)

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

FIGURE 4 - SAMPLE PIPING LAYOUT: MULTIPLE BOILERS IN A COMMON HYDRONIC LOOP, RETURN TEMPERATURE >140 F (60 C)

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-9

INSTALLATION CAL-IOM-2012-1220 SECTION 2

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

The boiler must be disconnected at

the boiler shut o valve from the gas supply piping system during any pressure testing of the system.

4 CAUTION

Small levels of chlorides and/or sulfur presence in the combustion air or fuel will negatively impact the heat exchanger components. Any presence of these contaminants will void the warranty.

Some soaps used for leak testing are corrosive to certain types of metals. Rinse all piping thoroughly with clean water after leak check has been completed.

Meet Water Chemistry Requirements

System water chemistry requirements are as follows:

§ Maximum hardness of 8.5 grains/150 ppm

§ Acceptable pH range of 7.5-10

§ Solids less than 2500 ppm

§ Alkalinity less than 500 ppm

§ Foreign matter: Oils, fats, grease, and other matter should be limited to 10

ppm.

Adhere to the following:

1. Refer to your water conditioning or chemical treatment supplier for analysis and recommendations for proper system conditions.

2. Follow a program with appropriate monitoring and maintenance of system water conditions as provided by your water conditioning or chemical treatment supplier.

3. Appropriate  ow rates and return water temperature may be achieved

through primary and secondary  ow loops. Please refer to Figures 3 - 4 for example systems. Multiple pumps, valves and heating zones operating at a variety of conditions will cause system  ow to vary. System design professionals should consider the variety of conditions the heating system will experience.

4. Operate the boiler in a closed-loop system using water or water/glycol (not requiring a make-up water supply). A large amount of improperly treated make-up water can cause premature failure of the heat exchanger resulting from scale build up. Scale build up will reduce the e ciency and useful life of the boiler.

2-10

5. Caliber boilers use high e ciency, small diameter tubing in the water side of the boiler. Large particulates may become caught in the heat exchanger, which could result in damage to the heat exchanger. Debris in the piping must be kept to a minimum; use a suitable strainer upstream of the inlet to the boiler.

TABLE 3  RECOMMENDED WATER TREATMENT CHEMICALS

Manufacturer Fernox Sentinel Sotin

Product

Inhibitor Protector/Alphi 11 X100, X500 Sotin 212

Universal Cleaner Restorer X300 --

Sludge Removal Protector.Restorer X400 Sotin 212

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

¡ Prevent Freezing

It is imperative to prevent freezing; adhere to the following:

§ If water/glycol is to be used in the system, a hazard analysis should be

performed to determine proper use and disposal. No greater than 50% glycol should be used.

§ Caliber boilers cannot be placed outdoors due to the potential for

condensate to freeze within the boiler. Precautions for freeze protection are recommended for boiler installations where freezing potential exists and for installations that will use sealed combustion with potential for outdoor air to fall below freezing point.

¡ Prevent Oxygen Contamination

There are several ways to prevent boiler water oxygen contamination:

§ Minimize system leaks to minimize make up water requirement

§ Do not use open tanks or  ttings

§ Do not use oxygen permeable materials anywhere in the water system

§ Repair leaks in the system quickly

§ Eliminate  ttings wherever possible

§ Use air elimination devices in system piping

¡ Eliminate System Air

There is a factory-installed air eliminator (air vent). The air eliminator must not be altered or removed. Additional air elimination recommendations are as follows:

4 CAUTION

Care needs to be taken to eliminate oxygen from the water system, as excess oxygen in the system will reduce the life of any boiler. The boiler warranty does not cover heat exchanger replacement due to oxygen contamination of boiler water.

Heat exchanger failure due to inappropriate water quality, foreign matter or debris damage is not covered under the warranty.

If the piping system attached to this unit will be chemically cleaned, the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler.

The hydronic system should never be

 ushed while the boiler is attached to the system since the debris could accumulate in the boiler and block water from passing through the heat exchanger. This will lead to premature boiler failure.

1. If a sealed diaphragm-type expansion tank is used, install an air eliminator in the hot water piping at the air separator.

2. If an air cushion type expansion tank is used, pipe tank directly into boiler supply.

3. On multi-zoned systems (or a system with both space and domestic water heating), air elimination must be provided either in the common piping or on every loop.

4. When the boiler is installed at a higher level than baseboard radiation (if used), air elimination must be provided directly above the unit.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-11

INSTALLATION CAL-IOM-2012-1220 SECTION 2

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations.

Do not use matches, candles,  ame or other sources of ignition to check for gas leaks.

DO NOT USE GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. If in doubt, contact your Fulton representative prior to operation.

4 CAUTION

Some soap used for leak testing is corrosive to certain types of metals. Clean all piping thoroughly after completing the leak check.

Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water damage could occur.

Fill the Boiler With Water

Adhere to the following:

1. Close combination shuto /purge valve in supply, all drain cocks, the shuto valve for the pressure reducing ( ll) valve, and all manual air vents.

2. Close the isolation valves to the boiler.

3. Open all other system shuto valves and one of the zone valves, the vent on the combination shuto /purge valve and the shuto valve to the pressure-reducing ( ll) valve.

4. Water will now begin to  ll the system. Air will escape through the vent on the combination shuto / purge valve. Continue  lling until a constant stream of water (no bubbling) is discharged from the vent.

5. Close the zone valve on the purged loop, and open the zone valve on the next loop to be purged. When all air has escaped and only water is discharged, close the zone valve. When all zones have been purged (one at a time), close the vent on the combination shuto /purge valve.

6. At this point, the system has been initially  lled. However, air pockets may still remain at high points in the system and in heating loops above the level of the combination shut/o purge valve. It is quite possible, depending on the particular system that all piping above the combination shuto /purge valve still contains air. If manual vents are installed on the system high points, these should be opened to vent these locations. When only water is discharged from all vents, the initial purging is complete.

The presence of chlorides and/or sulphur in the combustion air or fuel will negatively impact the heat exchanger and void the warranty.

Circulating pump power supply must be external to the boiler. The use of the SOLA as a power supply is prohibited. The pump contacts provided with the SOLA are for controlling the pump only.

7. Open the combination shuto / purge valve (keep the vent closed). With the gas shuto valve closed, turn on power to the boiler and operate the circulator. Circulate the system water for approximately 30 minutes to move all air to the automatic air separation point.

8. Again, open manual air vents at high points of heating loop until a constant stream of water is discharged from the vent. Close the vent and make sure it’s watertight. Repeat procedure for all high points and for every zone.

9. Due to the nature of the heat exchanger utilized in the Caliber Hydronic Boiler, pockets of air may still be trapped in the heat exchanger. To discharge this air,  rst open the automatic air vent located on the header of the heat exchanger one full turn.

10. Cycle the circulator pump on for approximately 30 seconds, then shut o for another 30 seconds. Repeat this step until no air is being discharged from the automatic air vent. This will take at least 5 full cycles.

11. Close the cap on the automatic air vent to prevent any leakage from occurring during normal operation.

12. Again, open manual air vents at high points of heating loop until a constant stream of water is discharged from the vent.

13. Check temperature/pressure indicator reading, which should equal the

2-12

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

pressure-reducing ( ll) valve set pressure (minimum 12 psig). No more water should be entering the system. Close the shuto valve on the cold-water  ll line.

14. Visually inspect all pipe joints and equipment connections for leaks. If necessary, drain system, repair leaks and re ll/purge the system. If no pressure drop is detected for a period of two hours under pressure, the system may be considered watertight.

15. When purging is completed, make sure the following are open—combination shut-o /purge valve, shuto valve to pressure reducing ( ll valve), shuto valve in cold water  ll line, and shuto valve in return line.

16. Make sure the following are closed--all drain cocks, the vent on the combination shuto purge valve, and all manual vents. Reset zone valves to normal mode of operation and turn o power to boiler.

17. Open fuel shuto valve, allowing fuel to  ow to boiler.

Install Gas Piping

The Caliber boiler is factory test  red and combustion is adjusted per the boiler data plate and test  re sheet.

The gas train (Figure 5) components are UL-795 certi ed to operate at speci c gas pressure requirements. If available gas pressure is greater than 14” W.C., a lock up style gas pressure regulator must be provided to reduce the provided pressure to the acceptable range of 3.5” W.C. to 14” W.C. for natural gas, and 7” W.C to 14” W.C. for propane.

Adhere to the following for gas piping installation:

overall length of pipe from the meter plus equivalent length of all  ttings. Approximate sizing may be based on 1,020 BTU for 1 cubic foot of natural gas.

2. Piping must be installed such that no piping stresses are transmitted to the boiler. The boiler cannot be used as a pipe anchor.

3. The boiler and all gas piping connections must be pressure-tested and checked for leaks before being placed into service. Test with compressed air or inert gas if possible.

4. The boiler must be disconnected at the boiler manual shuto valve (located at the end of the supplied gas train) from the gas supply piping system during any pressure testing of the system at pressures in excess of 1/2 psig (14 inch W.C.).

5. Gas piping must be installed in accordance with National Fuel Gas Code, ANSI Z223.1 1991 or latest addenda and any other local codes, which may apply.

6. The pipe and the  ttings used must be new and free of dirt or other deposits.

7. Piping must be of the proper size to ensure adequate gas supply. A drip leg and union connection must be installed upstream of the gas safety shut o valves.

8. Connect gas supply line to the open end of the tee on which the drip leg is installed.

9. When making gas-piping joints, use a sealing compound resistant to lique ed petroleum gases. Do not use Te on tape on gas line threads.

1. See Table 4 for required natural gas pipe size, based on

TABLE 4  NOMINAL PIPE SIZE

Nominal Pipe Size

(“) (“) 90 Elb

1-1/4 1.380 3.45 6.9 950 ----- ----- ----- ----- ----- -----

1-1/2 1.610 4.02 8.04 1460 990 810 ----- ----- ----- -----

2 2.067 5.17 10.3 2750 1900 1520 1300 1150 950 800

2-1/2 2.469 6.16 12.3 4350 3000 2400 2050 1850 1500 1280

3 3.068 7.67 15.3 7700 5300 4300 3700 3250 2650 2280

4 4.026 10.1 20.2 15800 10900 8800 7500 6700 5500 4600

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

ID Equivalent Pipe

Length

Tee

(Feet)

Max Capacity in ft3 of natural gas per hour. Pressure drop of

0.5”wc/Equivalent length of pipe (feet)

20 40 60 80 100 150 200

10. After gas piping is completed and before wiring

2-13

INSTALLATION CAL-IOM-2012-1220 SECTION 2

Ball Valve

Gas Valve

Gas Inlet

installation is started, carefully check all piping connections, (factory and

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Do not store or use gasoline or other

 ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances. Cements for plastic pipe should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors.

 eld), for gas leaks. Use a soap and water solution.

Never use open  ame or smoke from a cigarette, cigar, or pipe as a testing method during boiler installation, operation, or maintenance.

4 CAUTION

Some soaps used for leak testing are corrosive. Rinse piping with clean water after leak testing is completed.

FIGURE 5  TYPICAL GAS TRAIN

Venting

Adhere to the following venting requirements:

1. The boiler can be installed with either sealed combustion or a conventional

venting arrangement. With either venting con guration, the di erence in pressure readings at the boiler exhaust connection and air intake connection cannot exceed 1.0” W.C. This equates to 70 feet (21.3 m) and 8 elbows when combining the distances on the air intake and exhaust with the piping diameters matching the standard connections.

2. The pressure at the boiler exhaust connection must not exceed 0.05” W.C. negative. This pressure must remain relatively constant throughout the operation of the boiler.

3. The boiler should not be operated with a negative pressure in the boiler room (unless there is sealed combustion [intake piped outside]). Pay particular attention to other equipment installed in the boiler room such as compressors and air handling units.

2-14

4. Consult your venting pipe supplier for assistance with sizing of vent materials and other potentially required accessories.

NOTE: ´ An air intake  lter is included as standard. The air intake  lter must be

inspected and, if required, cleaned and/or replaced on a monthly basis at a minimum.

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

¡ Combustion Air Supply From the Boiler Room

Adhere to the following for installation:

1. Adequate combustion air and ventilation must be supplied to the boiler room in accordance with local codes and NFPA54/ANSI Z233.1, Section 5.3, Air for combustion and ventilation.

2. The boiler room must meet the NFPA criteria for a non-con ned space.

3. It is important to provide free access of air to the boiler. To burn fuel properly, it requires one square inch opening of fresh air for every 1,000 BTU input of fuel (no greater than 100 square inches).

4. Consistent proper ventilation of the boiler room is essential for good combustion. Install two fresh air openings, one at a low level, within 12

inches (305 mm) from the  oor but not less than 3 inches (76 mm), and one at a higher level within 12 inches (305 mm) of the ceiling but not less than 3 inches (76 mm) in the boiler room wall. This will provide a  ow of air to exhaust the hot air from the boiler room. Each opening must have a minimum of 1in2 per 1000 Btu/hr and be no less than 100in2.

5. Consider the blocking e ect of louvers and grills.

¡ Combustion Air Piped From Outside Building Without Sealed

Combustion

Adhere to the following for installation:

1. If the boiler room is deemed a con ned space two permanent ducts

connected to the outdoors must be installed.

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Do not use the boiler/burner as support for ducted air piping. Ducted piping must be supported independently of the boiler.

Do not terminate venting into an enclosed area.

Foreign substances, such as combustible volatiles in the combustion system can create hazardous conditions. If foreign substances can enter the air stream, the boiler combustion air inlet must be piped to an outside location.

Regular maintenance of the  lter is required (as per the  lter manufacturer’s recommendations) to maintain the warranty.

NOTE: ´ Assembly should be completed within 20 seconds after last application of

cement. Do not use a hammer to insert pipe.

2. After assembly, wipe excess cement from pipe at end of  tting socket. A properly made joint will show a bead around its entire perimeter. Any

gaps may indicate a defective assembly due to insu cient cement. Handle joints carefully until completely set. Galvanized steel joints should be sealed with adhesive aluminum tape.

¡ Air Piped From Outside Boiler Room

Adhere to the following:

1. The combustion air supply can be piped directly to the air inlet (Figure 3) of the boiler.

2. A rubber air intake coupling is recommended with boilers speci ed for installation with ducted air supply. It must be used to connect the intake piping to the boiler air inlet. This rubber air inlet coupling is available from Fulton as an option.

Particulate matter or chemicals in the combustion air supply to the boiler will cause damage or failure to the burner and is not covered under warranty.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-15

INSTALLATION CAL-IOM-2012-1220 SECTION 2

3. The air intake must be piped out of the building if the boiler room contains

! WARNING

contaminated air. See Figure 6.

Do not use the boiler as support for ducted air piping. Ducted piping must be supported independently of the boiler.

Cements for plastic pipe are

 ammable liquids and should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors. Avoid contact of cement with skin and eyes.

Exhaust Venting

The Caliber boiler is equipped with a round vent connection (Figure 7) at the lower rear of the boiler.

¡ Standard Venting Conﬁ guration, Category IV

The Caliber boiler is standardly con gured as a Category IV appliance. The vent connection sizes are adequate for a Category IV arrangement. Venting material must be appropriate for condensing, positive pressure applications (condensing occurs in the stack).

Adhere to the following:

1. The boiler requires a category IV stack. The Caliber comes factory set up with a stack temperature limiting function. The factory set point for this stack limit is 149 degrees Fahrenheit, which is appropriate for PVC venting. If CPVC venting is used, the installer should change this setpoint to 194 degrees Fahrenheit. If stainless venting is used, the stack material must be either AL-29-4C or 316L stainless steel and comply with UL-1708 or UL103, and the stack temperature limit function may be disabled. Venting installation must comply with National Fuel Gas Code, ANSI Z233.1, Part 10 or applicable provisions of local building codes.

2. Do not utilize automatic vent dampers or barometric dampers with the Caliber boiler. Because the exhaust system operates at a positive pressure, utilizing dampers could result in exhaust leaking into the boiler room.

3. The exhaust line must be sloped down toward the drain with a pitch of at least 1/4” per foot. Failure to do so can result in a condensate pocket, which can result in an inoperative boiler. There must be no low spots in the exhaust pipe, as this can also result in a condensate pocket. A high spot is acceptable, provided the pitch from the high spot is maintained back to the boiler. Always avoid rigid connections between piping and structural members of the building. The exhaust vent installer should be familiar with Federal Codes as well as local codes and regulations.

4. Follow vent manufacturer’s instructions for installation of exhaust venting. Refer to Table 5 for acceptable venting materials.

TABLE 5  ACCEPTABLE VENTING MATERIALS

Venting Material Max. Flue

Temperature

PVC 200 F (93 C) 200 F (93 C)

CPVC 200 F (93 C) 200 F (93 C)

Polypropylene 215 F (102 C) 200 F (93 C)

AL294C 215 F (102 C) 200 (93 C)

Max. Water Setpoint

2-16

Note: Fulton accepts no liability for installation of any venting, including the selection of venting materials.

If PVC is used, the  rst 8” must be CPVC.

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

FIGURE 6  COMBUSTIBLE WALL PENETRATION DETAILS

5. Stainless steel or galvanized steel pipe is recommended for all condensate drain piping. Copper and CPVC are acceptable for common headers only. Be aware that condensate drain piping can be as hot as the exhaust stack on the boiler, and precautions should be taken to ensure this pipe would not cause burns or other injuries to personnel that may be in the boiler room.

6. Ensure that the condensate drain piping will not be exposed to temperatures where water/condensate will freeze in the lines.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

¡ Sizing Air Intake and Exhaust Piping

} CATEGORY IV INSTALLATIONS, INDIVIDUAL PIPING FOR EACH

BOILER:

The minimum  ue stack length is 5 feet and the combined pressure drop of the air intake and exhaust piping should not exceed 1.0”wc. This is typically the equivalent of 70 ft and 8 elbows (combining the distances between the intake and exhaust pipes). If a negative pressure is present in the stack during some operating conditions, it should never be below

-0.04”wc.

2-17

INSTALLATION CAL-IOM-2012-1220 SECTION 2

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Use of automatic vent dampers or barometric dampers with the Caliber boiler in positive pressure systems may result in exhaust leaking into the boiler room.

It is critical to  ll the condensate trap with water prior to the  rst time the boiler is started up. Failure to do so

could allow  ue gas products into the boiler installation space, resulting in personal injury or death.

4 CAUTION

Failure to slope the exhaust line toward the drain with a pitch of at least 1/4” per foot may result in a condensate pocket, which can result in an inoperative boiler.

¡ Common Air Intake and Exhaust Venting of Multiple Boilers

Combining multiple Caliber boilers into a common pipe for combustion air supply, exhaust, or both is only permitted on a case by case basis and must be accomplished with a Fulton-engineered solution. A Common Venting Kit purchased from Fulton is required.

Adhere to the following:

1. The engineered solution must guarantee the prevention of  ue gases moving backwards through idle boilers. This is important to prevent  ue gases from entering the mechanical room (if sealed combustion is not being used) and also to prevent  ue gases from corroding the heat exchanger and/or other components in the upper cabinet of the boiler.

2. Caliber boilers should not be common vented with other types of equipment.

¡ Intake Duct Sizing

Adhere to the following:

1. Air intake ducting must be sized in conjunction with the exhaust venting to provide no greater than a 1.0” W.C. combined pressure drop. This equates to 70 feet and 8 elbows when combining the distances on the air intake and exhaust with the piping diameters matching the standard connections.

2. The installation of a recognized termination screen is required. Contact your local venting supplier for assistance in venting sizing.

3. Air Intake pipes and  ttings shall be Schedule 40 PVC pipe or galvanized

steel. All Schedule 40 PVC pipe,  ttings, primer and cement must conform with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM standards.)

2-18

4. Intake PVC piping must be assembled using cement. This will ensure that the intake is airtight and will not allow contaminates from the boiler room

into the boiler. The cement shall be free  owing and contain no lumps,

un-dissolved particles or any foreign matter that adversely a ects the joint strength or chemical resistance of the cement. The cement shall not show

gelation, strati cation, or separation that cannot be removed by stirring.

5. Refer to PVC manufacturer’s requirements for proper installation.

Condensate Drain Piping

A condensate trap and drain is integral to the boiler. The trap is located inside the cabinet, and the drain connection is at the back of the boiler, directly under the

 ue. All condensate piping is to be pitched away from this drain connection to ensure proper draining.

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

NOTE: ´ The trap can optionally be equipped with a high condensate alarm

functionality, which will annunciate via the SOLA control if there is something preventing the condensate from draining away properly.

Adhere to the following for condensate drain piping installation:

1. A condensate collecting tank and condensate pump will be required if a

 oor drain is not available to discharge to (Collecting tank and pump are not supplied with the boiler). Complete condensate drain kits are available from Fulton.

2. It is recommended that all condensate piping be galvanized or stainless steel and should be free of leaks.

3. High temperature silicone tubing (500 F) can be used on the outlet of the boiler to the header.

4. CPVC is acceptable for the common header only.

5. Install the condensate piping to the condensate drain in the lower left hand side of the boiler.

6. Connect 3/4” condensate drain(s) to the 1” header connected in a manifold. The header must be at least 5 1/2” below the condensate outlet of the

individual boiler and must remain  ooded by being at least 5 ½” below the outlet of the condensate drain trap.

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Fulton cannot assume responsibility for an air intake or exhaust arrangement where Caliber boilers are common vented with any other type of equipment.

Cements for plastic pipe are

 ammable liquids and should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors. Avoid contact of cement with skin and eyes.

Venting Terminations

Adhere to the following for installation (see Figure 7):

1. All vent pipes and  ttings must be installed with appropriate air space clearances to combustibles. These air space clearances apply to indoor or outdoor vents—whether they are open, enclosed, horizontal or vertical or pass through  oors, walls, roofs, or framed spaces. The air space clearances should be observed to joists, studs, sub oors, plywood, drywall or plaster enclosures, insulating sheathing, rafters, roo ng, and any other material classed as combustible.

2. The required minimum air space clearances also apply to electrical wires and any kind of building insulation.

3. Adequate provision must be made to support the weight of the exhaust venting. It cannot be supported by the boiler exhaust connection.

4. Listed termination parts must be used.

5. Select the air intake point of penetration where a minimum of 1/4” per foot upward pitch can be maintained.

6. When penetrating a non-combustible wall, the hole through the wall must be large enough to maintain the pitch of the vent and provide sealing. Use adhesive material to seal around the vent on both sides of the wall. When penetrating a combustible wall, a wall thimble must be used. See Figure 8for installation instructions. Minimum wall thickness through which vent

4 CAUTION

Circulating pump power supply must be external to the boiler. The use of the SOLA as a power supply is prohibited. The pump contacts provided with the SOLA are for controlling the pump only.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-19

INSTALLATION CAL-IOM-2012-1220 SECTION 2

system may be installed is 3.25 inches (82.5 mm). Maximum wall thickness

! WARNING

The exhaust vent installer should be familiar with Federal Codes as well as local codes and regulations.

Fulton cannot assume responsibility for an air intake or exhaust arrangement where Caliber boilers are common vented with any other type of equipment.

4 CAUTION

To prevent the possible re-circulation of  ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building con gurations, etc. It is the responsibility of the installer to locate the exhaust duct in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions.

through which vent system may be installed is 20 inches (508 mm).

Do not locate the vent termination too close to shrubbery as  ue products may stunt their growth or kill them.

FIGURE 7  VENTING TERMINATIONS

¡ Wall Thimble Installation

Adhere to the following for installation (see Figure 8):

1. The thimble is inserted through the wall from the outside. Secure the

outside  ange to the wall with nails or screws, and seal with adhesive material.

2. Install the inside  ange to the inside wall, secure with nails or screws, and seal with adhesive material.

3. Pass the vent pipe through the thimble from the outside and join to the rest of the vent system.

2-20

4. Seal the pipe to the thimble  ange with adhesive material.

5. Install two pipe retaining clamps around the intake as well as vent pipes

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

on both ends of the wall thimble (on the inside and outside of the wall) through which intake and vent pipes are passed. They will prevent the intake and vent pipes from being pushed or pulled.

¡ Horizontal Vent Termination

Adhere to the following for installation:

1. The vent termination is joined to the vent pipe outside the wall. Use the

same joining procedures for vent pipe and  ttings. The termination of the vent system must be at least 12 inches (304.8 mm) above the  nished grade, or at least 12 inches (304.8 mm) above normal snow accumulation level (for applicable geographical areas). The termination of the vent system shall not be located in tra c areas such as walk ways, adjacent buildings, operable windows and building openings unless the venting system is at least 7 ft (21.3 m) above  nished grade, (National Fuel Gas Code, ANSI Z223.1). The vent terminations must be at least 4 feet (1.22 m) horizontally from electric meters, gas meters, regulators, and relief equipment. See Figure 9.

2. When installing inlet and exhaust terminations on the same wall, the exhaust outlet must be installed 3 ft (.914 m) minimum above and downwind from air supply inlet to prevent exhaust recirculation. Under

certain wind conditions, some building materials may be a ected by  ue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (such as an aluminum sheet) may be required to prevent staining or deterioration.

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the boiler.

3. Do not locate the vent termination too close to shrubbery as  ue products may stunt their growth or kill them.

4. The minimum vent height should extend at least 3 ft (.914 m) above the roof, or at least 2 ft (.609 m) above the highest part of any structure within 10 ft (3.04 m) of the vent.

5. If the exhaust vent terminates within 10 ft (3.04 m) horizontally of the air inlet, the exhaust vent must be at least 4 ft (1.22 m) above the inlet. Dimensions listed above and those illustrated are minimum, and may or

may not be su cient for conditions at a speci c job site.

6. To prevent the possible re-circulation of  ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones,

building con gurations, etc. Fulton cannot be responsible for the e ects such adverse conditions may have on the operation of the boilers. It is important to locate the exhaust duct in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-21

INSTALLATION CAL-IOM-2012-1220 SECTION 2

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Do not use any dangerous source of  re or smoke (e.g., lighter, candle) to test equipment at any time.

Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the boiler.

4 CAUTION

Electrical Connections

Adhere to the following when installing electrical connections:

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

2. This boiler requires an independent 120V 60Hz single phase connection. Connect power to the terminal strip as supplied on the inside cover of the panel box.

3. Refer to Figure 3 for location of customer electrical connection.

NOTE: ´ Connect a ground wire to green colored ground lug in electrical control

box.

Never install a barometric damper on  ue systems designed with positive pressure.

2-22

SECTION 2 CAL-IOM-2012-1220 INSTALLATION

DIAMETER "C"

STAINLESS

3 1/2 IN. OR

4.35 CM

AIR GAP

ALL AROUND

THRU PIPE

VARIABLE

(3 1/4 IN. MIN.) - (20 IN. MAX.)

(8.255 CM MIN. - 50.8 CM MAX.)

DIAMETER "B"

ADJUSTABLE

WALL THUMBLE

WIDTH TO VARY WITH

WALL THICKNESS

DIAMETER "A"

COLLAR

END VIEW

SCREW OR BOLT EACH THUMBLE COLLAR

TO WALL (TYPICAL 4 PLACES) ORIENT

COLLAR AND CLAMPS AS REQUIRED

PIPE RETAINING CLAMP, TYPICAL EACH SIDE

FIGURE 8  WALL THIMBLE INSTALLATION

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-23

INSTALLATION CAL-IOM-2012-1220 SECTION 2

ROOF

SUPPORT

WIRES AND INSULATION

TO COMBUSTABLES,

AIR SPACE CLEARANCES

MAINTAIN MIN 9" / 22.86 CM

NOTE:

AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPERATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS.

4FT / 122 CM

FLASHING

ADJUSTABLE

4" PVC PIPE

FLASHING

ADJUSTABLE

ADHESIVE SEAL

STORM COLLAR

EXHAUST STACK IS DOWNWIND

OF AIR INTAKE OPENING

SCREENED INLET

MIN 4FT / 122 CM

ABOVE AIR INTAKE

PIPING

METAL PLATE

FIRE STOP

DO N OT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE

TYPICAL ROOF PENETRATIONS

( SUGGESTED TERMINATION CONFIGURATIONS )

IF SNOW ACCUMULATION IS APPLICABLE, OPENING TO BE 1 FT. / 30 CM ( MIN. ) ABOVE THIS NORMALLY EXPECTED LEVEL.

FIGURE 9  ROOF PENETRATION DETAILS

2-24

OPERATION

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE WARRANTY & PARTS

3

4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-1

OPERATION CAL-IOM-2012-1220 SECTION 3

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations. Failure to follow instructions may result in a  re or explosion, causing property damage, personal injury, or loss of life.

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines o ered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

Perform Pre-Start-Up Inspection

Prior to start-up, perform the following:

1. Smell all around the boiler area for gas. Be sure to smell next to the  oor, as some gas is heavier than air and will settle. If you smell gas:

» Do not try to light any appliance.

» Do not touch any electrical switch; do not use any phone in your

building.

» Immediately call your gas supplier from a neighbor’s phone.

2. Ensure the boiler is located with the proper clearances as shown in the Clearances and Serviceability section of this manual.

3. Ensure that relief valves have been properly piped to  oor drains.

4. Ensure  ue gas from the boiler is properly vented.

5. Ensure the water system has been  ushed and is free of debris.

6. Ensure combustion air openings are not obstructed in any way and have adequate capacity.

7. Ensure there are no  ammable liquids, materials or hazardous fumes present in the environment.

This boiler is equipped with an ignition device, which automatically lights the burner. Do not try to light the burner by hand.

Do not store or use gasoline or other  ammable vapors and liquids in the vicinity of this or any other appliances.

WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Do not touch any electrical switch; do not use any phone in your building. • Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the  re department. A quali ed installer, service agency or the gas supplier, must perform installation and service.

Do not use this boiler is any part has been underwater. Immediately contact a quali ed service technician.

8. Ensure nothing was damaged or knocked loose during installation and/or shipment, including main gas train and trim assembly.

Fill and Purge the System

Refer to Installation section of this manual for procedure. Attempting to start

the boiler prior to Fill and Purge may result in dry  re, which can cause injury or property damage, and is not covered by warranty.

SOLA Control Program Presets

The SOLA control (Figures 11) has been factory-programmed and requires no alteration of program presets. Only factory-trained personnel should attempt to alter password protected preset values.

Commission The Boiler

Adhere to the following when commissioning the boiler:

1. Verify with authorized personnel that the gas lines have been purged. Do not proceed without veri cation.

2. Familiarize all personnel on all aspects of boiler use, safety, and contents of this manual. This includes, but is not limited to, the use of the controls, lighting, and shutdown procedures.

3-2

SECTION 3 CAL-IOM-2012-1220 OPERATION

3. Review the unit-speci c control schematics, and follow appropriate instructions.

Test of Ignition Safety System

Test the ignition system safety shuto as follows:

1. Remove the black plug/connector from the main gas valve (it is held on with a central screw).

2. With the main gas cock (inlet manual gas valve) open, the burner should be cycled on. After all the safety limits such as gas pressure, water  ow and

temperature are satis ed, the blower will run and pre-purge the boiler.

3. Once the purge is complete (15-30 seconds), the ignition transformer will be energized. There will be a 4 second trial for ignition period.

4. The main gas valve will not open because there is no power to the valve due to the disconnected wires. Hence, no  ame will be established and the  ame safeguard will not receive a  ame signal from the UV scanner.

5. After 4 seconds, the  ame safeguard programmer will assume a “Flame Failure” condition and go to a “lockout” mode. Lockout will require manual reset of the  ame safeguard. The control will allow one retry before locking out.

6. After completing this test, turn o the boiler and reconnect the wires to

the main gas valve.

! WARNING

Do not attempt to start the boiler for any testing before  lling and purging the boiler. A dry  re will seriously damage the boiler and may result in property damage or personnel injury and is not covered by warranty.

Before commissioning the boiler, verify with authorized personnel that the gas lines have been purged.

Never attempt to operate a boiler that has failed to pass all the safety checks.

Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water damage could occur.

Check daily that the equipment area is free and clear of any combustible

materials, including  ammable vapors and liquids.

Perform Test of Low Water Cut Oﬀ

This boiler is equipped with a  ow switch type low water cut-o in the outlet nozzle. Once the boiler is full of water the following test can be accomplished:

1. Turn the boiler o .

2. Turn system pump o .

3. Turn the boiler back on. Boiler will begin to pruge, at which point it will lock out, annunciating “ilk o :  ow switch”. Reset lockout, and turn pump back on.

4. Perform appropriate test for any external or factory-installed probe-type low water cut-o .

Perform Test of Limit Controls

Fire the boiler and test the high limit control as follows:

1. Access the High Limit screen of the SOLA control.

2. Alter high temperature limit to a value lower than the anticipated loop temperature. Turn the boiler on. Water temperature will rise until the boiler locks out. This condition has to be manually reset. Alter the high

4 CAUTION

Do not use this equipment if any part has been under water (or subjected to heavy rains/water if the equipment does not have NEMA 4 wiring, controls and instrumentation). Immediately

call a quali ed service technician to inspect the equipment and to replace any part of the control system and/or gas control(s) which have been under water.

Commissioning/Start up by a nonFulton authorized person will void the product warranty.

Please read these instructions and post in an appropriate place near the equipment. Maintain in good legible condition.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-3

OPERATION CAL-IOM-2012-1220 SECTION 3

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

After checking controls by manual adjustment, make sure they are always reset to their proper settings.

Use only your hand to turn the valve handle. Never use tools. If the knob will not turn by hand, don’t try to repair it. Call a quali ed service technician. FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION.

limit cut o temperature to normal level, typically 10-20 degrees above set point.

Perform Test of Low Gas Pressure Switch

Test the low gas pressure switch as follows:

1. With the boiler running increase the low gas pressure setpoint until a lock out is annunciated.

2. Reset the switch to normal level, re-start the boiler.

Perform Test of High Gas Pressure Switch

Test the high gas pressure switch as follows:

1. Close the downstream main gas cock and start the boiler.

2. Once the trial for ignition period is reached, the main gas valve will open, pressurizing the line. This will trip the high gas pressure switch.

3. Manually reset the high gas pressure switch after it trips.

Perform Test of Air Switch

Fire the boiler and test the air switch as follows:

1. At low  re turn the adjustment on the switch clockwise until the switch trips and the boiler shuts down.

2. Back out the adjustment to previous position.

Test of High Back Pressure Switch

Fire the boiler and test the high back pressure switch as follows:

1. At high  re turn the adjustment on the switch counter clockwise until it opens and the boiler shuts down.

2. Turn the adjustment in two turns.

Normal Operation of the Boiler

Under normal operating circumstances, this boiler functions as a fully automatic appliance. The automatic control senses the water outlet temperature and  res the boiler when heat is needed by the system. Additionally this boiler may function as part of an integrated building management system.

3-4

Outlet water temperature, fan speed and set point are displayed on the SOLA touch screen display on the front of the boiler. Figure 10 shows a sample screen display on the SOLA control.

SECTION 3 CAL-IOM-2012-1220 OPERATION

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

When making changes to the controls

pro le, a combustion analyzer is required.

FIGURE 10  SAMPLE SCREEN OF SOLA CONTROL

¡ CHANGING THE OPERATING SET POINT

From the main screen do the following:

1. Tap “Con gure.”

2. Tap “Central Heat Con guration.”

3. Tap “CH Set Point.”

4. Tap “Clear.”

5. Enter New Set Point.

6. Tap “OK.”

7. Tap the escape arrow in top right hand corner (see Figure 11).

FIGURE 11  CHANGING THE OPERATING SET POINT

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-5

OPERATION CAL-IOM-2012-1220 SECTION 3

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

This boiler is equipped with an ignition device which automatically lights the burner. Do not try to light burner by hand.

¡ SETTING COMBUSTION

To Set Combustion, perform the following:

1. Obtain the following tools: Calibrated combustion analyzer, manometer to measure inlet gas pressure.

2. From home screen tap “Operation.”

3. Tap the yellow background “rpm” box next to  ring rate.

4. Under “Firing Rate Control” tap “Manual in Run.” Refer to Figure 12.

FIGURE 12  SETTING COMBUSTION ON SOLA CONTROL

5. Using test  re sheet enter the light o rpm’s in the “Manual Firing Rate” box.

6. Once the rpm’s are entered tap “OK”, then return to the home screen.

7. Turn the local/o /remote switch to the local position.

8. Once burner has started and you have veri ed  ame signal return to the “Manual Firing Rate” box.

9. Increase the  ring rate in 500 rpm increments until you reach the high  re rpm’s from the factory test  re sheet.

10. At each point check combustion. CO2/CO should remain constant throughout  ring range.

11. Monitor inlet gas pressure during combustion.

12. Once the high  re rpm setting is reached make  ne tuning adjustments on the gas ratio valve “ ow rate” to match factory test  re settings. The “ ow rate” adjustment requires a 3mm hex wrench.

NOTE: ´ Turning the screw counterclockwise increases gas  ow, clockwise

decreases gas  ow.

3-6

SECTION 3 CAL-IOM-2012-1220 OPERATION

NOTE: ´ The acceptable combustion range of CO2 is 8.0% to 9.8%. To maintain

NOx < 20%, set combustion to approximately 8.4% CO2. Site -speci c factors may

contribute to the determination of the appropriate combustion range of CO2, and other combustion parameters.

NOTE: ´ Combustion changes are made at high and low  re only, as the gas ratio

valve has a 1:1 ratio.

13. Manually decrease the  ring rate by 500 rpm increments observing combustion down to the low  re rpm setting (minimum) on the factory test  re sheet. If required low  re combustion may be altered by adjusting

the o set adjustment screw with either a Torx®T40 or a 5mm hex wrench.

NOTE: ´ Turning the screw counterclockwise decreases gas  ow, clockwise

increases gas  ow.

14. Before leaving the “Firing Rate” screen, tap “Automatic”  ring rate control. Do not leave the unit in the “Manual in Run” mode.

Shut Down Procedures

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/ professional codes and regulations.

4 CAUTION

Only factory-trained personnel should attempt to alter password protected Control preset values.

¡ Normal Shut Oﬀ Procedures

1. Place the local/o /remote switch in the o position.

2. Close all manual gas valves.

3. Turn o electrical power.

¡ Emergency Shut Oﬀ Procedures

The main gas cock should be closed immediately. If overheating occurs or the gas supply fails to shut o , do not turn o or disconnect the electrical supply to the pump. Instead, shut o the gas supply at a location external to the boiler.

¡ Shutting the Boiler Down for an Extended Period of Time

If the boiler is to be shut o for a period greater than 3 months:

1. Perform normal shut down procedure, see above.

2. Isolate water supply and  ow circuit from boiler.

3. Drain boiler.

4. Disconnect electrical supply.

¡ Starting Boiler After Prolonged Shutdown

Perform initial start up procedures as described in this manual.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-7

OPERATION CAL-IOM-2012-1220 SECTION 3

SOLA Control Features

Refer to the Table below for additional SOLA Control screen displays.

¡ Viewing the Flame Signal

1. The  ame signal can be viewed from the main/home screen or in main screen “details.

2. Tap “Details” in main screen then scroll to right by pressing the arrow until the “Flame Detection” is displayed.

3. Tap the escape arrow in top right hand corner to return to main operating screen

¡ Cycle and Run Hours

Monitoring

Burner cycles, burner run time, and pump cycles can be viewed from the

Statistics Con guration screen on the Control.

¡ Boiler Naming

3-8

SECTION 3 CAL-IOM-2012-1220 OPERATION

¡ Delta T Limit

¡ Stack Limit

¡ Lead/Lag Conﬁ guration

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-9

OPERATION CAL-IOM-2012-1220 SECTION 3

¡ Modbus Conﬁ guration

3-10

MAINTENANCE

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE

WARRANTY & PARTS

3

4

5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-1

MAINTENANCE CAL-IOM-2012-1220 SECTION 4

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Prior to any maintenance concerning electrical components of this equipment, ensure electrical supply to the equipment is disconnected. Label all wires prior to disconnection; wiring errors may cause improper and hazardous operation.

Follow all proper lockout/tagout procedures for service.

Before beginning any maintenance, ensure area is free of any combustible materials and other dangers.

What to do if you smell gas: Do not try to light the appliance. Do not touch any electrical switch. Do not use any phone in the building. Leave building and contact gas supplier from neighbor’s phone. If you cannot reach gas supplier, phone the  re department.

General

Your Caliber boiler has been designed to provide years of trouble free

performance. To ensure continued safety and e ciency of the boiler, please follow the maintenance and inspection directions outlined in this section of the manual.

Daily Maintenance and Inspection Schedule

Daily maintenance and inspection must include the following:

1. Observe operating temperature and general conditions.

2. Make sure that the  ow of combustion and ventilating air to the boiler is

not obstructed.

3. Assure that boiler area is free and clear of any combustible materials, including  ammable vapors and liquids.

Weekly Maintenance and Inspection Schedule

Weekly maintenance and inspection must include the following:

1. Observe the conditions of the main  ame. A normal high  re  ame shows an orange screen with a blue halo. In Low  re the burner should display a reddish orange glow.

2. Correct air adjustment is essential for the e cient operation of this boiler. If an adjustment to the combustion is necessary, the  ue gas composition should be checked with a carbon dioxide (CO2) or oxygen (O2) analyzer to set conditions.

After initial start-up by quali ed personnel, control settings and fuel pressures should not be readjusted.

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

4-2

Monthly Maintenance and Inspection Schedule

Monthly maintenance and inspection must include the following:

1. View  ame detection strength via the SOLA Control. See Operation section of this manual for screen details.

1. Test high-limit control by reducing setting below the operating temperature. Burner should shut o . Return high limit to previous setting.

2. Test operating temperature control by reducing temperature setting as necessary to check burner operation.

3. Check  ue gas temperature at outlet. If there is a temperature increase over previous readings, the probable cause is soot or water-scale build-up on the tubes. Consult Fulton Heating Solutions immediately if there is a concern.

4. Test low gas pressure switch and high gas pressure switch utilizing the procedure in operation section.

SECTION 4 CAL-IOM-2012-1220 MAINTENANCE

5. Test the water  ow switch by trying to restart boiler with system pump o . The boiler should not operate.

6. If an air inlet  lter is included with the boiler, inspect and clean  lter of any dust or lint. See Procedure for Cleaning the Air Inlet Filter.

7. Verify the water loop style traps in the exhaust venting system are  ooded.

Procedure for Cleaning the Air Inlet Filter

The air  lter is an optional part and does not come with every boiler.

Proceed as follows:

1. Remove the  lter. The  lter sits in a custom slot on the air inlet connection to the boiler, accessible from rear of boiler.

2. Remove all debris and dirt from the  lter using a non-corrosive soap and water.

3. Return the  lter to its original position in the slot.

Relief Valve Testing

The relief valve should be tested as per manufacturer instructions or every two months by lifting the lever for 5 seconds and allowing the valve to snap shut. Please see the manufacturer’s recommendations on the relief valve tag.

Annual Maintenance and Inspection Schedule

Annual maintenance and inspection must be performed prior to each heating season, and includes the following tasks which must be done by a factory trained technician.

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

Heat exchanger is heavy and may cause injury if improperly handled. Only trained and experienced personnel should perform removal of the heat exchanger.

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines o ered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

Observe the general operation of the unit to verify the following:

1. Stack temperature readings are in line with factory test  re and regular maintenance reports.

2. Boiler is lighting o reliably and quietly.

3. There are no unusual sounds coming from the burner or blower assembly.

4. It is considered good practice to remove and inspect the burner and ignition assembly on an annual basis. Follow Procedure for Removing/ Cleaning Burner in this manual if there is evidence of foreign matter built up on the burner or ignition assembly.

5. The heat exchanger must be inspected and cleaned, as needed. Follow the Procedure for Cleaning Heat Exchanger in this manual.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4 CAUTION

Use caution when using any cleaning solutions. Refer to local regulations for proper cleaning solution disposal.

Do not allow oil leaks, dust, or dirt to accumulate around the boiler.

Hazard analysis should be performed by end user to ensure safety of employees/personnel.

Any damage to the burner or any other aspect of the boiler because of

an air  lter that was not cleaned and maintained regularly will void the warranty on the Caliber boiler.

4-3

MAINTENANCE CAL-IOM-2012-1220 SECTION 4

! WARNING

Follow proper lockout / tag out procedures for the electrical, gas and water connections. Use caution when lifting heavy parts.

Never use open  ame or other sources of ignition to check for gas leaks.

4 CAUTION

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

¡ Examine the Venting System

1. Check all joints and pipe connections for tightness.

2. Check vent for corrosion or deterioration. If any venting needs replacing, do so immediately.

3. Perform any recommended maintenance as required by the vent material manufacturer.

4. Check to ensure loop traps are  ooded.

¡ Inspect Heating System for Other Problems

1. Perform combustion analysis and adjust if necessary.

2. Leak test gas valves. Leak Test must be performed only by quali ed

personnel, who have been trained in this procedure in a Fulton Service School.

Procedure for Removing/Cleaning The Burner

Perform the following to remove/clean the burner:

1. Remove front and side panels from the boiler outer jacket.

2. Disconnect both wire plug connectors to the pre-mix blower.

3. Disconnect the  ame rod, ignition wire and ground wire block.

4. Disconnect air sensing tubing from Venturi mixing unit, carefully swing the tubing away.

5. Disconnect air switch sensing tubing between switch and Venturi mixing unit inlet.

6. Disconnect the four bolts between the Venturi mixing unit  ange and the gas train  ange. Verify the gas train is properly supported prior to removing the above-mentioned four bolts, also verify supply gas is isolated. Inspect gasket located between these two  anges for signs of deterioration.

7. Undo four nuts holding pre-mix blower to the burner/blower mounting plate. Use care, the pre-mix blower/venturi-mixing unit is heavy. Inspect gasket for signs of deterioration.

8. Remove the nuts securing the burner door to the heat exchanger.

9. Remove burner, being careful not to scrape burner on heat exchanger. Inspect gasket for signs of deterioration.

10. Inspect burner and wipe o (do not scrub or use wire brush) any soot or

foreign material that may have accumulated. If available, use compressed air to clear the burner. Wipe out the inside of the burner with a clean cloth.

11. Check the horizontal gap between the point of ignition and the exterior of

4-4

SECTION 4 CAL-IOM-2012-1220 MAINTENANCE

the mesh burner. The required gap is 5/16-3/8-inch (8-10mm).

12. Use a soft, clean cloth to remove accumulated contaminants from the sight glass.

13. Before re-installing the burner, check the cleanliness of the heat exchanger and the condition of the combustion chamber. If corrosion or leaks are noticed, contact Fulton Heating Solutions.

14. Reverse removal steps for reinstallation of the burner assembly.

15. Reinstall front and side jacket panels.

16. Test  re the boiler and use a combustion analyzer to ensure that the fuel/

air ratio is set correctly throughout the range. Refer to the Fulton Heating Solutions factory test  re report for combustion settings.

Procedure for Cleaning Heat Exchanger

Inspect the heat exchanger, and clean if necessary using the following procedure:

1. Shut down the boiler, and allow for the heat exchanger to cool.

2. Remove the pre-mix blower by detaching the gas train via the four  ange

bolts on the Venturi, and the four  ange bolts on the fan discharge  ange.

4 CAUTION

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

3. Remove the nuts on the heat exchanger door.

4. Remove the heat exchanger door, with the burner, ignition assembly,  ame rod and blower  ange all still attached.

5. Inspect the tubes for any signs of damage.

6. Vacuum out any deposits inside the combustion chamber area if necessary.

7. If there is a buildup of any kind on the heat exchanger tubes, clean using a

dry, sti nylon bristle brush. Never use a metallic brush on heat exchanger surfaces.

8. Vacuum again to remove any debris from brushing the heat exchanger.

9. Wipe down with a clean wet cloth.

10. Inspect the refractory at the back of the combustion chamber.

11. If there are any signs of damage, the insulation disc must be replaced.

12. Inspect blower  ange gasket, and burner door gasket for signs of wear or

damage. Replace if damaged.

13. If the ignition assembly or  ame rod were removed for any reason, inspect these gaskets for signs of damage, and replace if damaged.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-5

MAINTENANCE CAL-IOM-2012-1220 SECTION 4

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

If any manual reset limit device trips, do not reset without determining and correcting the cause. These include

 ame safeguard, high or low gas pressure, and high temperature limit.

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative.

After All Repairs and Maintenance

1. Follow “Pre-Start Check List” provided with the unit, and all Safety Checks.

2. Fire the Boiler and perform combustion check. Analyze combustion throughout the range and verify proper operation of safety devices.

3. Make any necessary adjustments.

Troubleshooting

Use the following tables as a guide to troubleshooting your boiler.

4-6

SECTION 4 CAL-IOM-2012-1220 MAINTENANCE

PROBLEM CAUSE CHECK/SOLUTION

Manual Reset limit device

trips

Power outage to the boiler

room

Gas Pressure alarm is

annunciated

Manual Reset Limits include: Flame safeguard, high

or low gas pressure, high temperature limit

Entire boiler system is disabled and de-energized. When power has returned, the boiler will restart

Either insu cient gas pressure or the gas pressure

to the manifold is too high for safe and proper

operation of the boiler. This shuts down the burner.

When gas pressure is restored, the annunciated

alarm will remain on and the boiler will remain

locked out until the gas pressure switch is manually

reset.

DO NOT reset without determining and correcting

the cause.

unless it was in lockout position at time of outage.

Locate cause and correct. In the event of a high

gas manifold pressure condition, quali ed service

personnel must correct the problem before

restarting the boiler.

High water temp alarm is

annunciated

Insu cient  ow of heat

transfer medium causes

lock out

Low Air Flow Supply Low Air is annunciated if the air ow switch detects

High Back Pressure Switch trip/boiler shutdown

Main ﬂ ame failure during ﬁ ring period

Igni" on Failure If UV scanner does not detect the ﬂ ame during the

Boiler water has exceeded both the operating and

high-limit temperature. When the water temperature

falls below the high-limit temperature, the boiler will

remain locked out until the controller is manually

reset.

Boiler requires minimum  ow; when required  ow is

resumed, boiler will resume operation.

low air ow through the boiler.

Excessive Vent Pressure This condi" on will automa" cally recycle, so

Main gas control valve is de-energized and the control goes into “lockout” mode. Flame failure occurs and the indicator is illuminated.

4-second trial-for-igni" on period, the gas valve and spark igni" on are de-energized. At this " me a safety lockout occurs.

Locate cause and correct. Once the SOLA control

is reset, the sequence returns to normal operation

provided that the other limits are satis ed.

Identify and correct.

The air switch has been factory set and should not be adjusted in the ﬁ eld.

An extended low air indica" on does not mean that the low air switch is defec" ve.

Check that blower is powered and feedback plugs are clipped into the blower.

Check that the burner is clean by observing through the venturi. Check the blower purge speed and low ﬁ re speed is correctly displayed on the touch screen.

Check for obstruc" ons in the vent.

Check for obstruc" ons in the air inlet.

the boiler will try to relight. The vent and heat exchanger should be checked for obstruc" ons and cleaned.

The programmer must be manually reset.

Iden" fy and correct; reset via the SOLA Control.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-7

WARRANTY & PARTS

INTRODUCTION

INSTALLATION

1 2

OPERATION MAINTENANCE

WARRANTY & PARTS

3 4

5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

5-1

PARTS & WARRANTY CAL-IOM-2012-1220 SECTION 5

! WARNING

Use of non-factory authorized replacement parts is not recommended for this equipment. Use of non-factory authorized parts may jeopardize safety and system performance, and voids the product warranty.

Parts

Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial number of your Fulton boiler ready. Factory-direct replacement parts must be used to ensure proper equipment operation and adherence with warranty requirements. Contact Fulton Companies at (315) 2985121 for further information.

5-2

SECTION 5 CAL-IOM-2012-1220 WARRANTY & PARTS

Standard Warranty for Fulton Caliber Hydronic Boilers

Warranty Valid for all Caliber Models

Ten (10) Year Thermal Shock Warranty

The Caliber pressure vessel is warranted against failure due to thermal shock for a period of Ten (10) years from the date of shipment from the factory. This warranty does not cover damage due to corrosion, scaling, sooting and/or improper installation, operation and maintenance.

Five (5) Year Pressure Vessel/Heat Exchanger Warranty

The pressure vessel and heat exchanger are covered against failures resulting from ﬂ ue gas corrosion and/or defective material or workmanship for a period of ﬁ ve (5) years from the date of shipment from the factory. Waterside corrosion or scaling is not covered. Fulton Heating Solutions (Fulton) will repair, replace, exchange or credit at our option, FOB factory, the pressure vessel as deﬁ ned above, provided this equipment has been installed, operated and maintained in accordance with the Installation, Operation and Maintenance manual.

Parts

Fulton will repair or replace any part of the Caliber boiler found to be defective in workmanship or material within 18 months of shipment from the factory or 12 months from startup (whichever comes ﬁ rst). Fulton shall be notiﬁ ed in writing as soon as any defect becomes apparent. Defective parts must be returned to Fulton for evaluation and warranty consideration.

General

Fulton shall be notiﬁ ed in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind.

These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if installed, operated, and maintained as outlined in the Fulton Installation and Operation Manual.

No Sales Manager or other representative of Fulton other than the Quality Manager or an ofﬁ cer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager.

This warranty is exclusive and in lieu of all other warranties, expressed or implied, including but not limited to the implied warranties of merchantability and ﬁ tness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of proﬁ ts or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective.

Excessive cycling will reduce the life of ANY boiler. Verify that your system is properly designed and check cycling rate according to maintenance procedures listed in this manual.

To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.

05/01/2012

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

5-3

WARRANTY & PARTS CAL-IOM-2012-1220 SECTION 5

THIS PAGE INTENTIONALLY LEFT BLANK

5-4

SECTION 5 CAL-IOM-2012-1220 WARRANTY & PARTS

THIS PAGE INTENTIONALLY LEFT BLANK

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

5-5

WARRANTY & PARTS CAL-IOM-2012-1220 SECTION 5

THIS PAGE INTENTIONALLY LEFT BLANK

5-6

No part of this Installation, Operation, and Maintenance manual

may be reproduced in any form or by any means without

permission in writing from the Fulton Companies.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal

Corporation are part of the Fulton Group of Companies, a global manufacturer

of steam, hot water and thermal  uid heat transfer systems.

The heat transfer innovators.

The Fulton Companies

972 Centerville Road, Pulaski, NY 13142 Call: (315) 298-5121 • Fax: (315) 298-6390

www.fulton.com

CAL-IOM-2012-1220

FULTON Caliber, Caliber 300, Caliber 500, Caliber 750, Caliber 850 Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual