Install Water Piping - FULTON Caliber Installation And Operation Manual

INSTALLATION
!
WARNING
Ensure tank return line is not clogged.
Obstructions in the line could cause
damage to the pump seal.
The discharge from the safety relief valve
must be arranged to ensure no danger
to personnel or equipment damage.
Provisions must be made to properly pipe
the safety relief discharge away from the
boiler to the point of discharge.
No shuto of any kind shall be placed
between the safety relief valve and
the boiler, or in the discharge pipe
between the valve and the atmosphere.
Doing so may cause an explosion from
overpressure.
The hydronic system should never be
ushed while the boiler is attached to the
system since the debris could accumulate
in the boiler and block water from passing
through the heat exchanger.
Ensure all labels on the boiler are legible.
All connections and safety devices, both
mechanical and electrical, must be kept
clean, with ease of access for inspection,
use and maintenance.
Do not store or use gasoline or other
ammable vapors and liquids or corrosive
materials in the vicinity of this or any other
appliances.
4
CAUTION
Low ow conditions will cause excessive
cycling, damage and failure of equipment.
Ensure water piping arrangements allow
for heat-up times at or below 30 seconds;
this will reduce condensation which may
contribute to equipment failure.
Circulating pump power supply must be
external to the boiler. The use of the SOLA
as a power supply is prohibited. The pump
contacts provided with the SOLA are for
controlling the pump only.
2-6

Install Water Piping

All water supplies contain some solids, dissolved gases or dissolved minerals.
These may promote corrosion, deposition and/or fouling of equipment. To
prevent these contaminants from impacting boiler performance, valve operation
and general pipe longevity, each location must be analyzed and treated
accordingly.
Adhere to the following for water piping installation:
1. Boiler has a maximum temperature di erential across the heat exchanger
at high re, and has a minimum ow requirement. Use Table 2 to identify
ideal ow rates for the Caliber boiler.
TABLE 2 IDEAL FLOW RATES/GALLONS PER MINUTE*
Caliber Model
GPM at Operating
Temperature of
20 F dT *
GPM at Operating
Temperature of
60 F dT (max dT)
*typical
2. Ensure piping arrangements allow for heat-up times at or below
30 seconds; this will reduce condensation which may contribute to
equipment failure.
3. Pipe unions and isolation valves are recommended on both water
connections for ease of service.
4. Install piping so that the boiler is not supporting any additional piping.
5. The top water connection on the back of the boiler is the hot water
outlet and must be connected as the supply to the system. The bottom
connection is the return/boiler inlet. See Figure 2.
6. Install a hot water circulator, remote mounted from boiler. Do not attach
directly to the boiler. Refer to Figures 3 and 4 for proper location of
circulators.
7. Install manual purging valves in all loops and zones. Install a pressure
reducing (automatic ll) valve in the cold water ll line to the boiler system.
Check that the proposed operation of zone valves, zone circulator(s) and
diverting valves will not isolate air separator(s) and/ or expansion tank(s)
from the boiler. Clearance from hot water pipes to combustibles must be at
least 6 inches (152.4 mm).
8. The boiler, when used in conjunction with a refrigeration system, must
be installed so the chilled medium is piped in parallel with the boiler with
appropriate valves to prevent the chilled medium from entering the boiler.
If the boilers are connected to heating coils, located in air handling units
where they may be exposed to refrigerated air circulation, such boiler
CAL-IOM-2012-1220
300 500
30 45
8.8 15.4
© The Fulton Companies 2012
SECTION 2
750 850
70 80
17.6 19.8