Fulton Caliber Condensing Hydronic Boiler User Manual

INSTALLATION AND
OPERATION MANUAL
Caliber
High E ciency Hydronic Boilers
300,000 - 850,000 BTU/HR
Serial/ National Board Number
Model
Sold To
Job Name
Date
CAL-IOM-2014-0129
CAL-IOM-2014-0129 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 ................................................................................................. 2-6
Install Water Piping .............................................................................................. 2-6
LOW WATER C UT OFF ...................................................................................................................2 7
Meet Water Chemistry Requirements .................................................................. 2-7
PREVENT FREEZING ...................................................................................................................2 11
PREVENT OXYGEN CONTAMINATION ........................................................................................ 211
ELIMINATE SYSTEM AIR ............................................................................................................212
Fill the Boiler With Water ................................................................................... 2-12
Install Gas Piping ................................................................................................ 2-13
Venting ............................................................................................................... 2-15
Combustion Air Intake ....................................................................................... 2-15
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................215
COMBUSTION AIR PIPED FROM OUTSIDE BUILDING WITHOUT SEALED COMBUSTION ........216
AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................ 216
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19
Condensate Drain Piping .................................................................................... 2-20
Venting Terminations ......................................................................................... 2-20
WALL THIMBLE INSTALLATION .................................................................................................221
VENT TERMINATION ..................................................................................................................222
Electrical Connections ....................................................................................... 2-24
Test of High Back Pressure Switch ........................................................................ 3-4
Normal Operation of the Boiler ............................................................................ 3-4
CHANGING THE OPERATING SET POINT .....................................................................................35
SETTING COMBUSTION ................................................................................................................ 35
Shut Down Procedures ......................................................................................... 3-7
NORMAL SHUT OFF PROCEDURES .............................................................................................3 7
EMERGENCY SHUT OFF PROCEDURES .......................................................................................38
SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ........................................38
STARTING BOILER AFTER PROLONGED SHUTDOWN ..................................................................3 8
SOLA Control Features .......................................................................................... 3-9
VIEWING THE FLAME SIGNAL .................................................................................................... 39
CYCLE AND RUN HOURS MONITORING .......................................................................................39
BOILER NAMING ..........................................................................................................................39
DELTA T LIMIT .............................................................................................................................310
STACK LIMIT ...............................................................................................................................310
LEAD/LAG 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
Procedure for Removing/Cleaning The Burner .................................................... 4-4
Procedure for Cleaning Heat Exchanger ............................................................... 4-5
After All Repairs and Maintenance ...................................................................... 4-5
Troubleshooting ................................................................................................... 4-6
Warranty & Parts 5-1
Parts ..................................................................................................................... 5-2
Standard Warranty for Fulton Caliber Hydronic Boilers ....................................... 5-3
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
Questions? Please Contact Your Local Manufacturer’s Representative
0-1
TABLE OF CONTENTS CAL-IOM-2014-0129
0-2
© The Fulton Companies 2014
INTRODUCTION
INTRODUCTION
1
INSTALLATION
2
OPERATION MAINTENANCE WARRANTY & PARTS
3 4 5
Questions? Please Contact Your Local Manufacturer’s Representative
1-1
INTRODUCTION CAL-IOM-2014-0129 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
© The Fulton Companies 2014
INSTALLATION
INTRODUCTION
1
INSTALLATION
2
OPERATION MAINTENANCE WARRANTY & PARTS
3 4 5
Questions? Please Contact Your Local Manufacturer’s Representative
2-1
INSTALLATION CAL-IOM-2014-0129 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:
Steel 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 element 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
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
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 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 requirements of all national, state and local codes established by the authorities having jurisdiction and/or the U.S. 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.
! 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.
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.
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, ETL) must be followed for proper clearances and serviceability for your boiler. Authorities having jurisdiction should be consulted before installations are made.
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.
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. Appropriate front, back, side (Figure 2), and top clearances must be maintained. This will allow access around the equipment to facilitate maintenance and a safe work environment. A six inch (152.4 mm) side
Questions? Please Contact Your Local Manufacturer’s Representative
2-3
INSTALLATION CAL-IOM-2014-0129 SECTION 2
TABLE 1  OPERATING REQUIREMENTS SEE TABLE NOTES ON PAGE 25
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)
X. Electrical Connection*
Y. Condensate Drain Connection* IN
MM
Amp Draw
I. Gas Connection* IN
283,500 472,500 708,750 803,250
297 495 743 842
120 200 300 340
4.0
14
500 630 719 729
227 286 326 331
518 662 757 772
235 300 343 350
0.75 .075 0.75 0.75
19 19 19 19
2.1 3.6 3.6 3.6
.75 1 1.25 1.25
4.0
14
120/60/1
120/60/1
120/60/1
4.0
14
4.0
14
MM
G. Water Inlet/Outlet Connection* IN
MM
J. Flue Connection (ID)* IN
MM
H. Air Intake Connection***(OD) IN
MM
A. Boiler Width (including feet)* IN
MM
B. Boiler Height* IN
MM
C. Boiler Depth (Cabinet)* IN
MM
19.0 25.4 31.75 31.75
1.25 1.5 2 2
31.75 38.1 50.8 50.8
4.25 4.25 5.875 5.875
108 108 149 149
4.5 4.5 4.5 4.5
114 114 114 114
34.5 34.5 34.5 34.5
876 876 876 876
51.6 51.6 51.6 51.6
1310 1310 1310 1310
31.25 44 57.25 57.25
793 1117 1454 1454
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© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
C
X
H
* Refer to Figure 2
D
A
Front View
36"
B
J
Y
G Outlet
G Inlet
I
Right Side ViewBack View
FIGURE 1 CALIBER HYDRONIC BOILER
36"
24"6"24"
24"6"
FIGURE 2 CALIBER HYDRONIC BOILER SIDE CLEARANCES
Table 1 Notes:
Speci cations and dimensions are approximate. We reserve the right to change speci cations and dimensions without notice.
*See Figure 1.
**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.
***Will accept 4” Fernco  tting.
Questions? Please Contact Your Local Manufacturer’s Representative
2-5
INSTALLATION CAL-IOM-2014-0129 SECTION 2
! WARNING
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.
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.
clearance is acceptable between one pair of Cailber boilers. A 24 in (610 mm) clearance is acceptable between pairs of Caliber boilers. Refer to Figure 2.
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 is shipped loose and must be  eld­mounted into the water outlet manifold.
Adhere to the following installation requirements:
1. The safety relief valve 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.
4 CAUTION
Low  ow conditions will cause excessive cycling, damage and failure of equipment.
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.
2-6
» Be supported by means other than the safety valve itself.
» Be piped to avoid danger of scalding personnel.
NOTE: Each boiler is shipped with a pressure-temperature gauge to be installed
in the outlet piping section of the boiler.
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
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
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 *
Minimum Required GPM
*typical
2. Pipe unions and isolation valves are recommended on both water connections for ease of service.
3. Install piping so that the boiler is not supporting any additional piping.
4. 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 1.
5. Install a dedicated hot water circulator, remote mounted from boiler. Do not attach directly to the boiler. Refer to Figures 3 through 5 for recommended location of circulators.
NOTE: The Caliber boiler must be installed in a manner
which hydraulically separates the boiler, or primary loop, from all other loops in the hydronic system. This arrangement generally requires a dedicated boiler circulator and primary/secondary piping.
30 45 70 80
8.8 15.4 17.6 19.8
to heating coils (located in air handling units where they may be exposed to refrigerated air circulation), such boiler 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.
8. 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.
9. 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 must be 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.
 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.
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
6. 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).
7. 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
Questions? Please Contact Your Local Manufacturer’s Representative
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.
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INSTALLATION CAL-IOM-2014-0129 SECTION 2
2-8
FIGURE 3  SAMPLE PIPING LAYOUT: SINGLE BOILER WITH PRIMARY/SECONDARY PIPING CONFIGURATION
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
FIGURE 4  SAMPLE PIPING LAYOUT: MULTIPLE BOILERS IN A COMMON HYDRONIC LOOP, PRIMARY/SECONDARY WITH REVERSE RETURN
Questions? Please Contact Your Local Manufacturer’s Representative
2-9
INSTALLATION CAL-IOM-2014-0129 SECTION 2
2-10
FIGURE 5  SAMPLE PIPING LAYOUT: MULTIPLE BOILERS IN A COMMON HYDRONIC LOOP, INDIRECT DOMESTIC HOT WATER
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
3. Appropriate  ow rates may be achieved through primary and secondary  ow loops. Please refer to Figures 3 - 5 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.
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
 Prevent Freezing
! 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.
It is imperative to prevent freezing; adhere to the following:
If a water/glycol mix 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. 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 temperature 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
Questions? Please Contact Your Local Manufacturer’s Representative
2-11
INSTALLATION CAL-IOM-2014-0129 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.
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.
The presence of chlorides and/or sulphur in the combustion air or fuel will negatively impact the heat exchanger and void the warranty.
 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:
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.
Fill the Boiler With Water
Adhere to the following:
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.
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.
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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.
© The Fulton Companies 2014
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