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.
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.
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
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 pressure-reducing ( ll) valve set pressure (minimum 12 psig). No more water should be entering the system. Close the shuto valve on the cold­water  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.
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.
16. Make sure the following are closed — all drain cocks, the vent on the combination shuto purge valve, and all manual vents.
17. Reset zone valves to normal mode of operation and turn o power 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 6) 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 4” 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:
1. See Table 4 for required natural gas pipe size, based on 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.
Questions? Please Contact Your Local Manufacturer’s Representative
2-13
INSTALLATION CAL-IOM-2014-0129 SECTION 2
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.
installation is started, carefully check all piping connections(factory and  eld) for gas leaks. Use a soap and water solution.
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.
10. After gas piping is completed and before wiring
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
ID Equivalent Pipe
Length
Te e
(Feet)
(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
FIGURE 6  TYPICAL GAS TRAIN
2-14
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
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.
4. Consult your venting pipe supplier for assistance with sizing of vent materials and other potentially required accessories.
Combustion Air Intake
! 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.
Never use open  ame or smoke from a cigarette, cigar, or pipe as a testing method during boiler installation, operation, or maintenance.
An air intake  lter may be purchased as an option. The air intake  lter must be inspected and, if required, cleaned and/or replaced on a monthly basis at a minimum.
 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 (not less 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 1 inch squared per 1000 Btu/hr, and be no less than 100 inches squared.
DO NOT USE GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. If in doubt, contact your Fulton representative prior to operation.
4 CAUTION
Some soaps used for leak testing are corrosive. Rinse piping with clean water after leak testing is completed.
5. Consider the blocking e ect of louvers and grills.
Questions? Please Contact Your Local Manufacturer’s Representative
2-15
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.
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.
For closet and alcove installations, CPVC, polypropylene, or stainless steel material must be used.
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.
 Combustion Air Piped From Outside Building Without Sealed
Combustion
Adhere to the following for installation:
1. If the boiler room is deemed to be a con ned space, two permanent ducts connected to the outdoors must be installed.
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.
NOTE: Assembly should be completed within 20 seconds after last application of
cement. Do not use a hammer to insert pipe.
 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. An optional rubber air intake coupling may be used with boilers speci ed for installation with ducted air supply to connect the intake piping to the boiler air inlet.
3. The air intake must be piped out of the building if the boiler room contains contaminated air. See Figures 7 and 8.
Regular maintenance of the  lter is required (as per the  lter manufacturer’s recommendations) to maintain the warranty.
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 warran ty.
Do not mix vent systems of di erent types or manufacturers.
Exhaust Venting
The Caliber boiler is equipped with a round exhaust vent connection (Figure 7) at the lower rear of the boiler.
 Standard Venting Confi guration, Category II or IV
The Caliber boiler is standardly con gured as a Category II or IV appliance. The vent connection sizes are adequate for a Category II or IV arrangement. Venting material must be appropriate for positive pressure applications where condensing occurs in the stack.
Adhere to the following:
1. The boiler requires a category IV stack. The Caliber is factory con gured with a stack temperature limiting function set to 200 degrees Fahrenheit, which is appropriate for PVC and CPVC venting materials. If stainless venting is used, the stack material must be either AL-29-4C or 316L stainless steel and comply with UL-1708 or UL-103, and the stack temperature limit function may be disabled. If PVC exhaust venting
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© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
is used, the  rst 8 inches (204 mm) must be CPVC material. 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 gases leaking into the boiler room.
3. The exhaust line must be sloped down toward the boiler 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
PVC 200 F (93 C) 200 F (93 C)
CPVC 200 F (93 C) 200 F (93 C)
Polypropylene (InnoFlue)
AL294C 550 F (287 C) 200 (93 C)
Max. Flue Temperature
248 F (120 C) 200 F (93 C)
Max. Water Setpoint
! WARNING
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.
4 CAUTION
Insulation should not be used on PVC, CPVC, or polypropylene materials as it may elevate pipe wall temperatures, resulting in the potential for vent material failure.
Appropriate cement must be used when joining PVC to CPVC materials.
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. Do not use cellular/foam core pipe.
5. Stainless steel or galvanized steel pipe is recommended for all condensate drain piping. 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.
 Sizing Air Intake and Exhaust Piping
 CATEGORY II OR 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 -0.05”wc.
Questions? Please Contact Your Local Manufacturer’s Representative
2-17
INSTALLATION CAL-IOM-2014-0129 SECTION 2
FIGURE 7  COMBUSTIBLE WALL PENETRATION DETAILS
 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 Fulton­engineered solution.
Fulton Part No. 2-30-002018 Common Venting Kit can be optionally installed at the factory on CAL-750 and CAL-850 models. The installation location is between the burner  ange and the blower motor. When the blower motor starts, it will overcome the valve that is magnetically closed (See Figure
9). When the blower motor is is o , gravity will cause the
2-18
check valve to close and prevent  ue gases from recirculating through an idle boiler. This component is required when Caliber boilers are common vented.
Adhere to the following:
1. The engineered solution must guarantee the prevention of  ue gases moving backwards through idle boilers. This is important in preventing  ue gases from entering the mechanical room if sealed combustion is not being used, as well as preventing  ue gases from corroding the heat exchanger or other components within the boiler cabinet.
2. Caliber boilers cannot be common vented with other types of equipment.
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
FIGURE 8  VENTING CONFIGURATIONS
 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.)
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.
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
Questions? Please Contact Your Local Manufacturer’s Representative
FIGURE 9  CHECK VALVE FOR COMMONVENTED BOILERS
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INSTALLATION CAL-IOM-2014-0129 SECTION 2
! WARNING
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.
he 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.
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. All condensate piping is to be pitched away from this drain connection to ensure proper draining.
NOTE: The trap is equipped with a high condensate alarm functionality, which
will annunciate via the SOLA control if the  ue gas condensate is not 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. Do not use copper or carbon steel piping.
3. Install the condensate piping to the condensate drain at the back of the boiler.
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.
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.
Do not locate the vent termination too close to shrubbery as  ue products may stunt their growth or kill them.
NOTE: Be aware that condensate drain piping may be as hot as the exhaust stack
on the boiler. Precautions should be taken to ensure this piping will not cause burns or other injuries to personnel in the boiler room.
4. Ensure that the condensate drain piping will not be exposed to temperatures at which the  ue gas condensate has the potential of freezing.
Venting Terminations
Adhere to the following for installation (see Figure 10):
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.
2-20
4. Listed termination parts must be used.
5. Select the air intake point of penetration where a minimum of 1/4” per foot
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
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 8 for installation instructions. Minimum wall thickness through which vent system may be installed is 3.25 inches (82.5 mm). Maximum wall thickness through which vent system may be installed is 20 inches (508 mm).
! 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
FIGURE 10  VENTING TERMINATIONS
 Wall Thimble Installation
Adhere to the following for installation (see Figure 11):
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.
Never install a barometric damper on  ue systems designed with positive pressure.
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.
Questions? Please Contact Your Local Manufacturer’s Representative
2-21
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.
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.
Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the boiler.
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 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.
 Vent Termination
Adhere to the following for installation:
1. 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 intake and exhaust terminations in such a way that it does not become blocked due to snow, ice, and other natural or man­made obstructions.
2. 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. See Figure 12. Dimensions provided are minimum, and may or may not be su cient for conditions at a speci c job site.
3. Consider the harmful e ects to landscaping/shrubbery from the slightly acidic nature of  ue gas condensate when locating the vent termination.
In addition, adhere to the following for Horizontal Installations:
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.
2-22
2. When installing inlet and exhaust terminations on the same wall, the exhaust outlet must be installed a minimum of 4 feet (1.22 m) 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.
In addition, adhere to the following for Vertical Installations:
1. 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.
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
A
SCREW OR BOLT EACH THUMBLE COLLAR
TO WALL (TYPICAL 4 PLACES) ORIENT
COLLAR AND CLAMPS AS REQUIRED
PIPE RETAINING CLAMP, TYPICAL
3 1/2 IN. OR
4.35 CM
AIR GAP
ALL AROUND
THRU PIPE
DIAMETER "C"
STAINLESS
EACH SIDE
DIAMETER "B"
ADJUSTABLE
WALL THUMBLE
WIDTH TO VARY WITH
WALL THICKNESS
END VIEW
DIAMETER "A"
COLLAR
VARIABLE
(3 1/4 IN. MIN.) - (20 IN. MAX.)
(8.255 CM MIN. - 50.8 CM MAX.)
FIGURE 11  WALL THIMBLE INSTALLATION
4FT / 122 CM
(MINIMUM)
4FT / 122 CM ABOVE AIR INTAKE PIPING
SCREENED INLET
IF SNOW ACCUMULATION IS APPLICABLE, OPENING TO BE 1 FT. / 30 CM ( MIN. )
BOVE THIS NORMALLY
EXPECTED LEVEL.
ADHESIVE SEAL
STORM COLLAR
ADJUSTABLE FLASHING
4" PVC PIPE
WHEN WITHIN 10 FT HORIZONTALLY
ROOF
SUPPORT
METAL PLATE
FIRE STOP
NOTE:
AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPERATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS.
EXHAUST STACK IS DOWNWIND
OF AIR INTAKE OPENING
TYPICAL ROOF PENETRATIONS
( SUGGESTED TERMINATION CONFIGURATIONS )
ADJUSTABLE FLASHING
DO N OT PLACE INSULATION IN REQUIRED AIR SPACE CLEARANCE
FIGURE 12 ROOF PENETRATION DETAILS
Questions? Please Contact Your Local Manufacturer’s Representative
MAINTAIN MIN 9" / 22.86 CM AIR SPACE CLEARANCES TO COMBUSTABLES, WIRES AND INSULATION
2-23
INSTALLATION CAL-IOM-2014-0129 SECTION 2
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 13 for a sample electrical diagram. Please note, Figure 13 is for general reference purposes only and is not to be used for construction purposes.
NOTE: Connect a ground wire to green colored ground lug in
electrical control box.
2-24
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
Questions? Please Contact Your Local Manufacturer’s Representative
2-25
INSTALLATION CAL-IOM-2014-0129 SECTION 2
2-26
A
B
C
FIGURE 12  EXAMPLE ELCTRICAL DRAWING  FOR REFERENCE PURPOSES ONLY
© The Fulton Companies 2014
SECTION 2 CAL-IOM-2014-0129 INSTALLATION
1
7
8
5
3
6
11
10
FIGURE 12  EXAMPLE ELCTRICAL DRAWING  FOR REFERENCE PURPOSES ONLY
Questions? Please Contact Your Local Manufacturer’s Representative
NOTES:
1. ( ) DENOTES FIELD WIRING BY OTHERS.
2. REMOVE FACTORY INSTALLED JUMPER FOR E-STOP CONNECTION.
3. FOR BMS INTERFACE IF LEAD/LAG IS USED, USE COM2 ON DISPLAY, IF STAND ALONE BOILER OR LEAD/LAG IS NOT USED BMS CONNECTS TO J3-MB1.
4. PB1 IS A COMBINATION PILOT LIGHT - PUSH BUTTON ASSEMBLY.
2-27
INSTALLATION CAL-IOM-2014-0129 SECTION 2
2-28
© The Fulton Companies 2014
OPERATION
INTRODUCTION
1
INSTALLATION
2
OPERATION
MAINTENANCE WARRANTY & PARTS
3
4 5
Questions? Please Contact Your Local Manufacturer’s Representative
3-1
OPERATION CAL-IOM-2013-1001 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.
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.
Perform Pre-Start-Up Inspection
Prior to start-up, perform the following:
1. Check around the boiler area for the scent of gas. Be sure to check 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.
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
3-2
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 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.
© The Fulton Companies 2014
SECTION 3 CAL-IOM-2013-1001 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 attached with a central screw).
2. With the main gas cock (inlet manual gas valve) open, a call for heat will cycle the burner on. After all the safety limits (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.
NOTE: The main gas valve will not open because there is no power to the
valve. As a result, no  ame will be established and the  ame safeguard will not receive a  ame signal from the  ame rod.
4. 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.
5. 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 dedicated boiler pump o .
3. Turn the boiler back on. Boiler will begin to purge, 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 setpoint to a value lower than the anticipated loop temperature. Turn the boiler on. Water temperature will rise until the
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? Please Contact Your Local Manufacturer’s Representative
3-3
OPERATION CAL-IOM-2013-1001 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.
boiler locks out. This condition has to be manually reset. Alter the high limit setpoint 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.
3. Restart 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 toward the low end of the scale until it opens and the boiler shuts down.
2. Set the scale to 50% above the point at which the switch opened in Step 1.
Normal Operation of the Boiler
3-4
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.
Excessive cycling will reduce the useful life of any piece of mechanical
© The Fulton Companies 2014
SECTION 3 CAL-IOM-2013-1001 OPERATION
equipment. Caliber boilers should be operated and controlled so that the boiler cycles less than 12,000 times per year.
Outlet water temperature, fan speed and set point are displayed on the SOLA touch screen display on the front of the boiler. Figure 14 shows a sample Status Screen display on the SOLA control.
! 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 14  SAMPLE STATUS SCREEN OF SOLA CONTROL
 CHANGING THE OPERATING SET POINT
From the main screen, perform the following steps:
1. Tap Con gure.
2. Tap Central Heat Con guration.
3. Tap CH Set Point.
4. Tap Clear.
5. Enter the New Set Point.
6. Tap OK.
7. Tap the escape arrow in top right hand corner (see Figure 15).
 SETTING COMBUSTION
To Set Combustion, perform the following steps:
1. Obtain the following tools: Calibrated combustion analyzer, manometer to measure inlet gas pressure.
2. From home screen tap Operation.
Questions? Please Contact Your Local Manufacturer’s Representative
3-5
OPERATION CAL-IOM-2013-1001 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.
3. Tap the yellow background rpm box next to  ring rate. (See Figure 16).
4. Under Firing Rate Control, tap Manual in Run. Refer to Figure 17.
FIGURE 15  CHANGING THE OPERATING SET POINT
3-6
FIGURE 16  LOCATION OF FIRING RATE/RPM BOX
FIGURE 17  SETTING COMBUSTION ON SOLA CONTROL
© The Fulton Companies 2014
SECTION 3 CAL-IOM-2013-1001 OPERATION
5. Using test  re sheet, enter the rpm value (light o ) in the Manual Firing Rate box.
6. Once the rpm value is entered, tap OK.
7. Return to the status screen.
8. Turn the local/o /remote switch to the local position.
9. Once burner has started and  ame signal has been veri ed, return to the Manual Firing Rate box.
10. Increase the  ring rate in 500 rpm increments until high  re rpm value from the factory test  re sheet is reached.
 At each point, check combustion. CO2/CO should remain constant
throughout  ring range. Monitor inlet gas pressure during combustion.
11. Once the high  re rpm setting is reached, make 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.
! 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.
NOTE: The acceptable combustion range of CO
maintain NOx < 20%, set combustion to approximately 8.4% CO
-speci c factors may contribute to the determination of the appropriate combustion range of CO
NOTE: Combustion changes are made at high and low  re only, as the gas
ratio valve has a 1:1 ratio.
12. Manually decrease the  ring rate by 500 rpm increments. Observe 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.
13. If changes are made (at either high or low  re), recheck the entire range.
14. Before leaving the Firing Rate screen, tap Automatic  ring rate control. Do not leave the unit in the Manual in Run mode.
2, and other combustion parameters.
2 is 8.0% to 9.8%. To
2. Site
Shut Down Procedures
 Normal Shut Off Procedures
1. Place the local/o /remote switch in the o position.
Questions? Please Contact Your Local Manufacturer’s Representative
3-7
OPERATION CAL-IOM-2014-0129 SECTION 3
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.
3-8
© The Fulton Companies 2014
SECTION 3 CAL-IOM-2014-0129 OPERATION
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 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 may be viewed from the Statistics Con guration screen on the Control.
 Boiler Naming
Questions? Please Contact Your Local Manufacturer’s Representative
3-9
OPERATION CAL-IOM-2014-0129 SECTION 3
 Delta T Limit
The maximum Delta T is 60 F.
 Stack Limit
 Lead/Lag Confi guration
3-10
© The Fulton Companies 2014
MAINTENANCE
INTRODUCTION
1
INSTALLATION
2
OPERATION
MAINTENANCE
WARRANTY & PARTS
3
4
5
Questions? Please Contact Your Local Manufacturer’s Representative
4-1
MAINTENANCE CAL-IOM-2014-0129 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 are 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 Fire, the burner should display a reddish-orange glow.
2. Ensure correct air adjustment. 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 an oxygen (O2) or carbon dioxide (CO2) 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 of this manual.
© The Fulton Companies 2014
SECTION 4 CAL-IOM-2014-0129 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 that the water loop style traps in the exhaust venting system are  ooded.
Procedure for Cleaning the Air Inlet Filter
NOTE: The air  lter is an optional part and does not come with every boiler.
Proceed as follows:
1. Remove the  lter. The  lter is accessible through the removal of the top or side access panels, and is located within a housing at the air inlet connection.
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
! 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.
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.
The relief valve should be tested 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 performed by a factory­trained technician.
Observe the general operation of the unit to verify the following:
1. Stack temperature readings are aligned 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.
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.
5. The heat exchanger must be inspected and cleaned, as needed. Follow the Procedure for Cleaning Heat Exchanger in this manual.
Questions? Please Contact Your Local Manufacturer’s Representative
4-3
MAINTENANCE CAL-IOM-2014-0129 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.
6. Perform combustion analysis per factory Test Fire Sheet. Make adjustments as necessary.
 Examine the Venting System
1. Check all joints and pipe connections for tightness and proper seal.
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.
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.
4-4
7. Undo four nuts holding pre-mix blower to the burner/blower mounting plate. Use care, as 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. Use caution to prevent scraping the burner on the 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 the mesh burner. The required gap is 5/16-3/8-inch (8-10 mm).
12. Use a soft, clean cloth to remove accumulated contaminants from the sight glass.
© The Fulton Companies 2014
SECTION 4 CAL-IOM-2014-0129 MAINTENANCE
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.
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.
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.
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.
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.
Questions? Please Contact Your Local Manufacturer’s Representative
4-5
MAINTENANCE CAL-IOM-2014-0129 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.
Troubleshooting
Use the following tables as a guide to troubleshooting your boiler.
4-6
© The Fulton Companies 2014
SECTION 4 CAL-IOM-2014-0129 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. Contact your local representative/
quali ed service technician.
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 temperature
alarm is annunciated
Insu cient  ow of heat
transfer medium causes
lock out
Low Air Flow Supply/ Air Switch Open
High Back Pressure Switch trip/boiler shutdown
Main fl ame failure during ring period
IgniƟ on Failure If fl ame rod 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 is annunciated if the air ow switch detects
low air ow through the boiler.
Excessive Vent Pressure This condiƟ on will automaƟ 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-igniƟ on period, the gas valve and spark igniƟ on are de-energized. At this Ɵ 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 indicaƟ on does not mean that the low air switch is defecƟ ve.
Check that blower is powered and feedback plugs are clipped into the blower.
Check that the blower 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 obstrucƟ ons in the vent.
Check for obstrucƟ ons in the air inlet.
the boiler will try to relight. The vent and heat exchanger should be checked for obstrucƟ ons and cleaned.
The programmer must be manually reset.
IdenƟ fy and correct; reset via the SOLA Control.
Questions? Please Contact Your Local Manufacturer’s Representative
4-7
WARRANTY & PARTS
INTRODUCTION
1
INSTALLATION
2
OPERATION MAINTENANCE
WARRANTY & PARTS
3 4
5
Questions? Please Contact Your Local Manufacturer’s Representative
5-1
PARTS & WARRANTY CAL-IOM-2014-0129 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.
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© The Fulton Companies 2014
SECTION 5 CAL-IOM-2014-0129 WARRANTY & PARTS
Standard Warranty for Fulton Caliber Hydronic Boilers
Warranty Valid for all Caliber Models
T en (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. W aterside 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? Please Contact Your Local Manufacturer’s Representative
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© The Fulton Companies 2014
SECTION 5 CAL-IOM-2014-0129 WARRANTY & PARTS
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Questions? Please Contact Your Local Manufacturer’s Representative
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© The Fulton Companies 2014
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 Fulton Companies 2014
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-2014-0129
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