Table Of Contents - FULTON Caliber Installation And Operation Manual

CAL-IOM-2012-1220
Introduction
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation
Product Overview ................................................................................................. 2-2
Placement & Rigging ........................................................................................... 2-3
Clearances and Serviceability .............................................................................. 2-3
Install Boiler Trim ................................................................................................. 2-5
Install Water Piping .............................................................................................. 2-6
LOW WATER CUT OFF ...................................................................................................................2 7
Meet Water Chemistry Requirements ................................................................ 2-10
PREVENT FREEZING ...................................................................................................................2 11
PREVENT OXYGEN CONTAMINATION ........................................................................................2 11
ELIMINATE SYSTEM AIR ............................................................................................................2 11
Fill the Boiler With Water ................................................................................... 2-12
Install Gas Piping ............................................................................................... 2-13
Venting ............................................................................................................... 2-14
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................2 15
COMBUSTION AIR PIPED FROM OUTSIDE BUILDING WITHOUT SEALED COMBUSTION ........2 15
AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................2 15
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 18
Condensate Drain Piping .................................................................................... 2-18
Venting Terminations ......................................................................................... 2-19
WALL THIMBLE INSTALLATION .................................................................................................2 20
HORIZONTAL VENT TERMINATION ............................................................................................2 21
Electrical Connections ....................................................................................... 2-22
Operation
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
Test of High Back Pressure Switch ........................................................................ 3-4
Questions? Call (315) 298-5121, or visit us online at www.fulton.com
1-1 Normal Operation of the Boiler ............................................................................ 3-4
CHANGING THE OPERATING SET POINT .....................................................................................3 5
SETTING COMBUSTION ................................................................................................................3 6
Shut Down Procedures ......................................................................................... 3-7
NORMAL SHUT OFF PROCEDURES .............................................................................................3 7
EMERGENCY SHUT OFF PROCEDURES .......................................................................................3 7
2-1
SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ........................................3 7
STARTING BOILER AFTER PROLONGED SHUTDOWN ..................................................................3 7
SOLA Control Features .......................................................................................... 3-8
VIEWING THE FLAME SIGNAL ....................................................................................................3 8
CYCLE AND RUN HOURS MONITORING .......................................................................................3 8
BOILER NAMING ..........................................................................................................................3 8
DELTA T LIMIT ...............................................................................................................................3 9
STACK LIMIT .................................................................................................................................3 9
LEAD/LAG CONFIGURATION .......................................................................................................3 9
MODBUS CONFIGURATION .......................................................................................................3 10
Maintenance
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
INSPECT HEATING SYSTEM FOR OTHER PROBLEMS ..................................................................4 4
Procedure for Removing/Cleaning The Burner .................................................... 4-4
Procedure for Cleaning Heat Exchanger ............................................................... 4-5
After All Repairs and Maintenance ...................................................................... 4-6
Troubleshooting ................................................................................................... 4-6
Warranty & Parts
Parts ..................................................................................................................... 5-2
3-1
Standard Warranty for Fulton Caliber Hydronic Boilers ....................................... 5-3

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