Fulton Caliber (CAL) Condensing Hydronic Boiler - Manual (Page 49)

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 4
CAL-IOM-2014-0129
MAINTENANCE
4-5
4
CAUTION
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.
All maintenance procedures should
be completed by trained personnel.
Appropriate training and instructions
are available from the Fulton Service
Department at (315) 298-5121 or your
local Fulton Representative.
In order to meet warranty conditions,
ensure all appropriate maintenance
activities are performed.
13. Before re-installing the burner, check the cleanliness of the heat exchanger
and the condition of the combustion chamber. If corrosion or leaks are
noticed, contact Fulton Heating Solutions.
14. Reverse removal steps for reinstallation of the burner assembly.
15. Reinstall front and side jacket panels.
16. Test fi re the boiler and use a combustion analyzer to ensure that the fuel/
air ratio is set correctly throughout the range. Refer to the Fulton Heating
Solutions factory test fi re report for combustion settings.
Procedure for Cleaning Heat Exchanger
Inspect the heat exchanger, and clean if necessary using the following procedure:
1. Shut down the boiler, and allow for the heat exchanger to cool.
2. Remove the pre-mix blower by detaching the gas train via the four fl ange
bolts on the Venturi, and the four fl ange bolts on the fan discharge fl ange.
3. Remove the nuts on the heat exchanger door.
4. Remove the heat exchanger door, with the burner, ignition assembly, fl ame
rod and blower fl ange all still attached.
5. Inspect the tubes for any signs of damage.
6. Vacuum out any deposits inside the combustion chamber area if necessary.
7. If there is a buildup of any kind on the heat exchanger tubes, clean using a
dry, stiff nylon bristle brush. Never use a metallic brush on heat exchanger
surfaces.
8. Vacuum again to remove any debris from brushing the heat exchanger.
9. Wipe down with a clean wet cloth.
10. Inspect the refractory at the back of the combustion chamber.
11. If there are any signs of damage, the insulation disc must be replaced.
12. Inspect blower fl ange gasket, and burner door gasket for signs of wear or
damage. Replace if damaged.
13. If the ignition assembly or fl ame rod were removed for any reason, inspect
these gaskets for signs of damage, and replace if damaged.
After All Repairs and Maintenance
1. Follow “Pre-Start Check List” provided with the unit, and all Safety Checks.
2. Fire the boiler and perform combustion check. Analyze combustion
throughout the range and verify proper operation of safety devices.
3. Make any necessary adjustments.