Fulton Caliber (CAL) Condensing Hydronic Boiler - Manual (Page 3)

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CAL-IOM-2014-0129
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 Boiler Trim ................................................................................................. 2-6
Install Water Piping .............................................................................................. 2-6
LOW WATER CUT 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
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 Off ....................................................................... 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
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