Questions? Please Contact Your Local Manufacturer’s Representative
1-1
INTRODUCTIONCAL-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.
Questions? Please Contact Your Local Manufacturer’s Representative
2-1
INSTALLATIONCAL-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.
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
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
INSTALLATIONCAL-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
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.
30457080
8.815.417.619.8
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.
2-7
INSTALLATIONCAL-IOM-2014-0129 SECTION 2
2-8
FIGURE 3 SAMPLE PIPING LAYOUT: SINGLE BOILER WITH PRIMARY/SECONDARY PIPING CONFIGURATION
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
ManufacturerFernoxSentinelSotin
Product
InhibitorProtector/Alphi 11X100, X500Sotin 212
Universal CleanerRestorerX300--
Sludge Removal Protector.RestorerX400Sotin 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
INSTALLATIONCAL-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.
2-12
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.