Fulton Caliber (CAL) Condensing Hydronic Boiler - Manual (Page 37)

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SECTION 3
CAL-IOM-2013-1001
OPERATION
3-3
!
WARNING
Do not attempt to start the boiler for
any testing before fi lling and purging
the boiler. A dry fi re will seriously
damage the boiler and may result in
property damage or personnel injury
and is not covered by warranty.
Before commissioning the boiler,
verify with authorized personnel that
the gas lines have been purged.
Never attempt to operate a boiler
that has failed to pass all the safety
checks.
Never leave an opened manual air
vent unattended. In the event an
opened vent is left unattended, water
damage could occur.
Check daily that the equipment area
is free and clear of any combustible
materials, including fl ammable
vapors and liquids.
4
CAUTION
Do not use this equipment if any part
has been under water (or subjected to
heavy rains/water if the equipment
does not have NEMA 4 wiring, controls
and instrumentation). Immediately
call a qualifi ed service technician to
inspect the equipment and to replace
any part of the control system and/or
gas control(s) which have been under
water.
Commissioning/Start up by a non-
Fulton authorized person will void the
product warranty.
Please read these instructions and
post in an appropriate place near the
equipment. Maintain in good legible
condition.
3. Review the unit-specifi c control schematics, and follow appropriate
instructions.
Test of Ignition Safety System
Test the ignition system safety shutoff as follows:
1. Remove the black plug/connector from the main gas valve (it is attached
with a central screw).
2. With the main gas cock (inlet manual gas valve) open, a call for heat will
cycle the burner on. After all the safety limits (gas pressure, water fl ow, and
temperature) are satisfi ed, the blower will run and pre-purge the boiler.
3. Once the purge is complete (15-30 seconds), the ignition transformer will
be energized. There will be a 4 second trial for ignition period.
NOTE:  The main gas valve will not open because there is no power to the
valve. As a result, no fl ame will be established and the fl ame safeguard will
not receive a fl ame signal from the fl ame rod.
4. After 4 seconds, the fl ame safeguard programmer will assume a “Flame
Failure” condition and go to a “lockout” mode. Lockout will require manual
reset of the fl ame safeguard. The control will allow one retry before locking
out.
5. After completing this test, turn off the boiler and reconnect the wires to
the main gas valve.
Perform Test of Low Water Cut Off
This boiler is equipped with a fl ow switch type low water cut-off in the outlet
nozzle. Once the boiler is full of water the following test can be accomplished:
1. Turn the boiler off .
2. Turn dedicated boiler pump off .
3. Turn the boiler back on. Boiler will begin to purge, at which point it will
lock out, annunciating
“ilk off : fl ow switch”. Reset lockout, and turn pump
back on.
4. Perform appropriate test for any external or factory-installed probe-type
low water cut-off .
Perform Test of Limit Controls
Fire the boiler and test the high limit control as follows:
1. Access the High Limit screen of the SOLA control.
2. Alter high temperature limit setpoint to a value lower than the anticipated
loop temperature. Turn the boiler on. Water temperature will rise until the