FULTON Caliber User 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

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CAL-IOM-2012-1220 TABLE OF CONTENTS
0-1
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 BoilerTrim ................................................................................................. 2-5
InstallWater Piping.............................................................................................. 2-6
LOWWATER CUT OFF...................................................................................................................27
MeetWater Chemistry Requirements................................................................ 2-10
PREVENT FREEZING...................................................................................................................211
PREVENT OXYGEN CONTAMINATION........................................................................................211
ELIMINATE SYSTEM AIR ............................................................................................................211
Fill the BoilerWithWater ................................................................................... 2-12
Install Gas Piping............................................................................................... 2-13
Venting............................................................................................................... 2-14
COMBUSTION AIR SUPPLY FROMTHE BOILER ROOM..............................................................215
COMBUSTION AIR PIPED FROM OUTSIDE BUILDINGWITHOUT SEALED COMBUSTION........215
AIR PIPED FROM OUTSIDE BOILER ROOM................................................................................215
ExhaustVenting ................................................................................................. 2-16
STANDARD VENTING CONFIGURATION, CATEGORY IV.............................................................216
SIZING AIR INTAKE AND EXHAUST PIPING...............................................................................217
COMMON AIR INTAKE AND EXHAUSTVENTING OF MULTIPLE BOILERS.................................218
INTAKE DUCT SIZING .................................................................................................................218
Condensate Drain Piping.................................................................................... 2-18
VentingTerminations......................................................................................... 2-19
WALL THIMBLE INSTALLATION.................................................................................................220
HORIZONTALVENTTERMINATION............................................................................................221
Electrical Connections ....................................................................................... 2-22
Operation 3-1
Perform Pre-Start-Up Inspection......................................................................... 3-2
Fill and Purge the System..................................................................................... 3-2
SOLA Control Program Presets............................................................................. 3-2
CommissionThe Boiler......................................................................................... 3-2
Test of Ignition Safety System.............................................................................. 3-3
PerformTest of LowWater Cut O ....................................................................... 3-3
PerformTest of Limit Controls ............................................................................. 3-3
PerformTest of Low Gas Pressure Switch ............................................................ 3-4
PerformTest of High Gas Pressure Switch............................................................ 3-4
PerformTest of Air Switch.................................................................................... 3-4
Test of High Back Pressure Switch........................................................................ 3-4
Normal Operation of the Boiler............................................................................ 3-4
CHANGINGTHE 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
SHUTTINGTHE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME........................................37
STARTING BOILER AFTER PROLONGED SHUTDOWN..................................................................37
SOLA Control Features.......................................................................................... 3-8
VIEWINGTHE FLAME SIGNAL ....................................................................................................38
CYCLE AND RUN HOURS MONITORING.......................................................................................38
BOILER NAMING ..........................................................................................................................38
DELTAT LIMIT...............................................................................................................................39
STACK LIMIT.................................................................................................................................39
LEAD/LAG CONFIGURATION .......................................................................................................39
MODBUS 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
ReliefValveTesting............................................................................................... 4-3
Annual Maintenance and Inspection Schedule................................................... 4-3
EXAMINETHE VENTING SYSTEM ................................................................................................44
INSPECT HEATING SYSTEM FOR OTHER PROBLEMS..................................................................44
Procedure for Removing/CleaningThe Burner.................................................... 4-4
Procedure for Cleaning Heat Exchanger............................................................... 4-5
After All Repairs and Maintenance ...................................................................... 4-6
Troubleshooting................................................................................................... 4-6
Warranty & Parts 5-1
Parts ..................................................................................................................... 5-2
Standard Warranty for Fulton Caliber Hydronic Boilers ....................................... 5-3

© The Fulton Companies 2012
TABLE OF CONTENTS CAL-IOM-2012-1220
0-2

Questions? Call(315)298-5121,or visit usonlineat www.fulton.com 1-1
INTRODUCTION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2012
1-2
INTRODUCTION CAL-IOM-2012-0518 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.

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INSTALLATION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
2-2
! 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.
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.
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:
§Lightweight casing utilizing an air gap as insulation
§Integrated combustion supervision and temperature operating control
§Operating and high temperature dual temperature 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
§Combustion Air Adapter
§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.

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SECTION 2 CAL-IOM-2012-1220 INSTALLATION
2-3
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 the requirements of all national, state and local codes
established by the authorities having jurisdiction and/or the U.S. to the
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. National Electrical
Manufacturers Association (NEMA) 3R Conguration is available as an
option from the factory, but an existing boiler cannot be retrotted for
outdoor installation.
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) must be
followed for proper clearances and serviceability for your boiler or heater.
Authorities having jurisdiction should be consulted before installations are
made.
! 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.
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.

© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
2-4
TABLE 1  OPERATING REQUIREMENTS
Caliber Model Size 300 500 750 850
Input (BTU/Hr) 300,000 500,000 750,000 850,000
Output (BTU/Hr) 283,500 472,500 708,750 803,250
Natural Gas Consumption (ft3/hr) 297 495 743 842
Propane Consumption (ft3/hr) 120 200 300 340
Gas Supply Pressure Minimum
Maximum
4.0
14
4.0
14
4.0
14
4.0
14
Dry Weight LB
KG 500 570 680 690
227 259 308 313
Operating Weight LB
KG 520 605 720 740
236 274 327 336
Control Voltage (V/Hz/Ph) 120/60/1
Blower Voltage (V/Hz/Ph) 120/60/1
Gas Connection IN
MM
1111
25.4 25.4 25.4 25.4
Water Inlet/Outlet Connection IN
MM
1.25 1.5 2 2
31.75 38.1 50.8 50.8
Flue Connection IN
MM
4466
101.6 101.6 152.4 152.4
Air Intake Connection IN
MM
4444
101.6 101.6 101.6 101.6
Boiler Width IN
MM
28 28 28 28
711.2 711.2 711.2 711.2
Boiler Height IN
MM
51 51 51 51
1295.4 1295.4 1295.4 1295.4
Boiler Depth (Cabinet) IN
MM
31.25 44 57.25 57.25
793.75 1117.6 1454.15 1454.15
Amp Draw 1.8 3.6 3.6 3.6
Notes:
Speci cations and dimensions are approximate. We reserve the right to change speci cations and dimensions without notice.
*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.

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SECTION 2 CAL-IOM-2012-1220 INSTALLATION
2-5
2. Appropriate front, back, side and top clearances
must be maintained (Figure 1). This will allow access
around the equipment to facilitate maintenance and
a safe work environment. A four inch (101.6 mm) side
clearance is acceptable between boilers.
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
comes pre-piped into the water outlet manifold.
Adhere to the following installation requirements:
1. The safety relief valve (Figure 1) 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.
» Be supported by means other than the safety
valve itself.
» Be piped to avoid danger of scalding personnel.
NOTE:´Each boiler is equipped with a pressure-temperature
gauge to be installed in the outlet piping section of the boiler.
FIGURE 1 CALIBER HYDRONIC BOILER CLEARANCES
36”
36”
SAFETY
RELIEF
VALVE
4”
AIR INLET
36”

© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
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 300 500 750 850
GPM at Operating
Temperature of
20 F dT *
30 45 70 80
GPM at Operating
Temperature of
60 F dT (max dT)
8.8 15.4 17.6 19.8
*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
! 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.

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SECTION 2 CAL-IOM-2012-1220 INSTALLATION
2-7
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.
9. 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.
10. 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 is 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.
FIGURE 2  CONNECTIONS
Air Inlet
Water Outlet
Connection
(System Supply)
Water Inlet
Connection
(System Return)
Customer Electrical
Connection
Exhaust Outlet
Connection

© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
2-8
FIGURE 3 - SAMPLE PIPING LAYOUT: SINGLE BOILER WITH RETURN WATER TEMPERATURE >140 F (60 C)

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SECTION 2 CAL-IOM-2012-1220 INSTALLATION
2-9
FIGURE 4 - SAMPLE PIPING LAYOUT: MULTIPLE BOILERS IN A COMMON HYDRONIC LOOP, RETURN TEMPERATURE >140 F (60 C)

© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
2-10
! 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.
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
§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.
3. Appropriate ow rates and return water temperature may be achieved
through primary and secondary ow loops. Please refer to Figures 3 - 4 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

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SECTION 2 CAL-IOM-2012-1220 INSTALLATION
2-11
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.
¡Prevent Freezing
It is imperative to prevent freezing; adhere to the following:
§If water/glycol 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 due to the potential for
condensate to freeze within the boiler. 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 air 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
§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.

© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
2-12
! 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 matches, candles, ame or
other sources of ignition to check for gas
leaks.
DO NOT USE GASOLINE, CRANKCASE OIL
OR ANY OIL CONTAINING GASOLINE. If in
doubt, contact your Fulton representative
prior to operation.
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.
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.
Fill the Boiler With Water
Adhere to the following:
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.
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.
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

Questions? Call(315)298-5121,or visit usonlineat www.fulton.com
SECTION 2 CAL-IOM-2012-1220 INSTALLATION
2-13
pressure-reducing (ll) valve set pressure (minimum 12
psig). No more water should be entering the system.
Close the shuto valve on the cold-water 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.
16. Make sure the following are closed--all drain cocks, the
vent on the combination shuto purge valve, and all
manual vents. Reset zone valves to normal mode of
operation and turn o power to boiler.
17. Open fuel shuto valve, allowing fuel to ow 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 5) 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 3.5”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.
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.
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
ID Equivalent Pipe
Length
Max Capacity in ft3 of natural gas per hour. Pressure drop of
0.5”wc/Equivalent length of pipe (feet)
(“) (“) 90 Elb
(Feet)
Tee
(Feet)
20 40 60 80 100 150 200
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

© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
2-14
! 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.
4 CAUTION
Some soaps used for leak testing are
corrosive. Rinse piping with clean water
after leak testing is completed.
installation is started, carefully check all piping connections, (factory and
eld), for gas leaks. Use a soap and water solution.
Ball Valve
Ball Valve
Gas Valve
Gas Inlet
FIGURE 5  TYPICAL GAS TRAIN
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.
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.