Fulton Caliber (CAL) Condensing Hydronic Boiler - Manual (Page 19)

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SECTION 2
CAL-IOM-2014-0129
INSTALLATION
2-13
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
fl 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.
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, fi 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 off 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
pressure-reducing (fi ll) valve set pressure (minimum 12 psig). No more
water should be entering the system. Close the shutoff valve on the cold-
water fi ll line.
14. Visually inspect all pipe joints and equipment connections for leaks. If
necessary, drain system, repair leaks and refi 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-off /purge valve, shutoff valve to pressure reducing (fi ll
valve), shutoff valve in cold water fi ll line, and shutoff valve in return line.
16. Make sure the following are closed — all drain cocks, the vent on the
combination shutoff purge valve, and all manual vents.
17. Reset zone valves to normal mode of operation and turn off power to
boiler.
Install Gas Piping
The Caliber boiler is factory test-fi red and combustion is adjusted per the boiler
data plate and test fi re sheet.
The gas train (Figure 6) components are UL-795 certifi ed to operate at specifi 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 4” 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 fi ttings. Approximate
sizing may be based on 1,020 BTU for 1 cubic foot of natural gas.