Fulton Caliber (CAL) Condensing Hydronic Boiler - Manual (Page 13)

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SECTION 2
CAL-IOM-2014-0129
INSTALLATION
2-7
ideal fl 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
Minimum
Required
GPM 8.8 15.4 17.6 19.8
*typical
2. Pipe unions and isolation valves are recommended on
both water connections for ease of service.
3. Install piping so that the boiler is not supporting any
additional piping.
4. 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 1.
5. Install a dedicated hot water circulator, remote
mounted from boiler. Do not attach directly to the
boiler. Refer to Figures 3 through 5 for recommended
location of circulators.
NOTE:

The Caliber boiler must be installed in a manner
which hydraulically separates the boiler, or primary
loop, from all other loops in the hydronic system. This
arrangement generally requires a dedicated boiler
circulator and primary/secondary piping.
6. Install manual purging valves in all loops and zones.
Install a pressure reducing (automatic fi ll) valve in the
cold water fi 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).
7. 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 piping systems shall be equipped with fl ow
control valves or other automatic means to prevent
gravity circulation of the boiler water during the cooling
cycle.
8. 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.
9. 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 must be
completely fl 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 fl ow-switch type
low water cut-off (LWCO). The LWCO does not require fi eld
piping or wiring. If the fl ow switch does not sense fl ow,
the boiler will shut down and an alarm condition will be
annunciated on the SOLA color screen display.
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.