Related Manuals for FULTON Caliber
Summary of Contents for FULTON Caliber
-
Page 1: Operation Manual
INSTALLATION AND OPERATION MANUAL Caliber High E ciency Hydronic Boilers 300,000 - 850,000 BTU/HR Serial/ National Board Number Model Fulton Order Sold To Job Name Date CAL-IOM-2012-1220... -
Page 3: Table Of Contents
Electrical Connections ..................2-22 Warranty & Parts Parts ........................5-2 Operation Standard Warranty for Fulton Caliber Hydronic Boilers ........5-3 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 ................ - Page 4 TABLE OF CONTENTS CAL-IOM-2012-1220 © The Fulton Companies 2012...
-
Page 5: Introduction
INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 6: Overview
Fulton reserves the right to change any part of of such requirements, in the US to the National Fuel Gas this installation, operation and maintenance manual. -
Page 7: Installation
INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 8: Product Overview
The Fulton Caliber boiler is constructed to ASME Section IV and certi ed by the Crystalline silica may be present in components of this equipment. -
Page 9: Placement & Rigging
Placement & Rigging All information in this manual is for Proper placement of your Fulton product is essential. Attention paid to reference and guidance purposes, the following points will save a great deal of di culty in the future. Correct... - Page 10 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. © The Fulton Companies 2012...
-
Page 11: Install Boiler Trim
Install Boiler Trim location. The discharge pipe must: » Not have a diameter less than the full area of the Each Caliber boiler is supplied with a safety relief valve sized valve outlet. in accordance with ASME requirements. The safety relief valve »... -
Page 12: Install Water Piping
Use Table 2 to identify ideal ow rates for the Caliber boiler. No shuto of any kind shall be placed TABLE 2 IDEAL FLOW RATES/GALLONS PER MINUTE*... -
Page 13: Low Water Cut Off
Water Outlet Connection 10. Before installing a Caliber boiler into a hydronic loop, be (System Supply) sure that the system piping and any other components of the system are clean and free of debris and any Water Inlet foreign matter. - Page 14 INSTALLATION SECTION 2 CAL-IOM-2012-1220 FIGURE 3 SAMPLE PIPING LAYOUT: SINGLE BOILER WITH RETURN WATER TEMPERATURE >140 F 60 C © The Fulton Companies 2012...
- Page 15 INSTALLATION SECTION 2 CAL-IOM-2012-1220 FIGURE 4 SAMPLE PIPING LAYOUT: MULTIPLE BOILERS IN A COMMON HYDRONIC LOOP, RETURN TEMPERATURE >140 F 60 C Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
-
Page 16: Meet Water Chemistry Requirements
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. -
Page 17: Prevent Freezing
Caliber boilers cannot be placed outdoors due to the potential for contamination of boiler water. condensate to freeze within the boiler. Precautions for freeze protection... -
Page 18: Fill The Boiler With Water
The pump contacts provided with the SOLA are for 9. Due to the nature of the heat exchanger utilized in the Caliber Hydronic controlling the pump only. 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. -
Page 19: Install Gas Piping
6. The pipe and the ttings used must be new and free of dirt or other deposits. The Caliber boiler is factory test red and combustion is 7. Piping must be of the proper size to ensure adequate adjusted per the boiler data plate and test re sheet. -
Page 20: Venting
NOTE: An air intake lter is included as standard. The air intake lter must be inspected and, if required, cleaned and/or replaced on a monthly basis at a minimum. 2-14 © The Fulton Companies 2012... -
Page 21: Combustion Air Supply From The Boiler Room
It must be used to connect the intake piping to the boiler air inlet. This rubber air inlet coupling is available from Fulton as an option. 2-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 22: Exhaust Venting
AL294C 215 F (102 C) 200 (93 C) 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. 2-16 © The Fulton Companies 2012... -
Page 23: Sizing Air Intake And Exhaust Piping
If a negative pressure is present in the stack freeze in the lines. during some operating conditions, it should never be below -0.04”wc. 2-17 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 24: Common Air Intake And Exhaust Venting Of Multiple Boilers
2. Caliber boilers should not be common vented with other types of equipment. It is critical to ll the condensate trap... -
Page 25: Venting Terminations
When penetrating a combustible wall, a wall thimble must be used. See Figure 8for installation instructions. Minimum wall thickness through which vent 2-19 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 26: Wall Thimble Installation
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. CAUTION To prevent the possible re-circulation... -
Page 27: Horizontal Vent Termination
6. To prevent the possible re-circulation of ue gases, the vent designer must take into consideration such things as prevailing winds, eddy zones, building con gurations, etc. Fulton cannot be responsible for the e ects such adverse conditions may have on the operation of the boilers. It is important to locate the exhaust duct in such a way that it does not become blocked due to snow, ice, and other natural or man-made obstructions. -
Page 28: Electrical Connections
NOTE: Connect a ground wire to green colored ground lug in electrical control powered down prior to attempting box. replacement or service of electrical components or connections of the boiler. CAUTION Never install a barometric damper on ue systems designed with positive pressure. 2-22 © The Fulton Companies 2012... - Page 29 WIDTH TO VARY WITH WALL THICKNESS DIAMETER "A" COLLAR VARIABLE (3 1/4 IN. MIN.) - (20 IN. MAX.) (8.255 CM MIN. - 50.8 CM MAX.) FIGURE 8 WALL THIMBLE INSTALLATION 2-23 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 30 4" PVC PIPE DO N OT PLACE INSULATION IN REQUIRED AIR METAL PLATE SPACE CLEARANCE FIRE STOP MAINTAIN MIN 9" / 22.86 CM AIR SPACE CLEARANCES TO COMBUSTABLES, WIRES AND INSULATION FIGURE 9 ROOF PENETRATION DETAILS 2-24 © The Fulton Companies 2012...
-
Page 31: Operation
OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 32: Perform Pre-Start-Up Inspection
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 2012... -
Page 33: Test Of Ignition Safety System
2. Alter high temperature limit to a value lower than the anticipated loop temperature. Turn the boiler on. Water temperature will rise until the boiler locks out. This condition has to be manually reset. Alter the high Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 34: Perform Test Of Low Gas Pressure Switch
CAL-IOM-2012-1220 WARNING limit cut o temperature to normal level, typically 10-20 degrees above set point. Non-Fulton product information is for reference purposes only. No Fulton Perform Test of Low Gas Pressure Switch document should substitute for full review of documentation available from the component manufacturer. -
Page 35: Changing The Operating Set Point
4. Tap “Clear. ” 5. Enter New Set Point. 6. Tap “OK. ” 7. Tap the escape arrow in top right hand corner (see Figure 11). FIGURE 11 CHANGING THE OPERATING SET POINT Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 36: Setting Combustion
SECTION 3 CAL-IOM-2012-1220 WARNING SETTING COMBUSTION To Set Combustion, perform the following: Non-Fulton product information is for reference purposes only. No Fulton 1. Obtain the following tools: Calibrated combustion analyzer, manometer to document should substitute for full measure inlet gas pressure. -
Page 37: Shut Down Procedures
2. Isolate water supply and ow circuit from boiler. 3. Drain boiler. 4. Disconnect electrical supply. Starting Boiler After Prolonged Shutdown Perform initial start up procedures as described in this manual. Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 38: Sola Control Features
Cycle and Run Hours Monitoring Burner cycles, burner run time, and pump cycles can be viewed from the Statistics Con guration screen on the Control. Boiler Naming © The Fulton Companies 2012... -
Page 39: Delta T Limit
OPERATION SECTION 3 CAL-IOM-2012-1220 Delta T Limit Stack Limit Lead/Lag Confi guration Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 40: Modbus Configuration
OPERATION SECTION 3 CAL-IOM-2012-1220 Modbus Confi guration 3-10 © The Fulton Companies 2012... -
Page 41: Maintenance
MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 42: General
WARNING General All information in this manual is for Your Caliber boiler has been designed to provide years of trouble free reference and guidance purposes, performance. To ensure continued safety and e ciency of the boiler, please and does not substitute for required... -
Page 43: Procedure For Cleaning The Air Inlet Filter
Procedure for Cleaning Heat Exchanger in this manual. 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. Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 44: Examine The Venting System
2. Leak test gas valves. Leak Test must be performed only by quali ed professional training, conduct, personnel, who have been trained in this procedure in a Fulton Service and strict adherence to applicable School. -
Page 45: Procedure For Cleaning Heat Exchanger
16. Test re the boiler and use a combustion analyzer to ensure that the fuel/ Appropriate training and instructions air ratio is set correctly throughout the range. Refer to the Fulton Heating are available from the Fulton Service Department at (315) 298-5121 or your Solutions factory test re report for combustion settings. -
Page 46: After All Repairs And Maintenance
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. © The Fulton Companies 2012... - Page 47 If UV scanner does not detect the fl ame during the Iden fy and correct; reset via the SOLA Control. 4-second trial-for-igni on period, the gas valve and spark igni on are de-energized. At this me a safety lockout occurs. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
-
Page 49: Warranty & Parts
WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 50: Parts
Fulton Companies. When ordering replacement parts, please have for this equipment. Use of non-factory the model number and serial number of your Fulton boiler ready. Factory-direct authorized parts may jeopardize safety replacement parts must be used to ensure proper equipment operation and and system performance, and voids the adherence with warranty requirements. -
Page 51: Standard Warranty For Fulton Caliber Hydronic Boilers
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. - Page 52 WARRANTY & PARTS SECTION 5 CAL-IOM-2012-1220 THIS PAGE INTENTIONALLY LEFT BLANK © The Fulton Companies 2012...
- Page 53 WARRANTY & PARTS SECTION 5 CAL-IOM-2012-1220 THIS PAGE INTENTIONALLY LEFT BLANK Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 54 WARRANTY & PARTS SECTION 5 CAL-IOM-2012-1220 THIS PAGE INTENTIONALLY LEFT BLANK © The Fulton Companies 2012...
- Page 56 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.