© The Fulton Companies 2012
INSTALLATION CAL-IOM-2012-1220 SECTION 2
2-12
! WARNING
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.
Do not use matches, candles, ame or
other sources of ignition to check for gas
leaks.
DO NOT USE GASOLINE, CRANKCASE OIL
OR ANY OIL CONTAINING GASOLINE. If in
doubt, contact your Fulton representative
prior to operation.
4 CAUTION
Some soap used for leak testing is corrosive
to certain types of metals. Clean all piping
thoroughly after completing the leak check.
Never leave an opened manual air vent
unattended. In the event an opened vent is
left unattended, water damage could occur.
The presence of chlorides and/or sulphur
in the combustion air or fuel will negatively
impact the heat exchanger and void the
warranty.
Circulating pump power supply must be
external to the boiler. The use of the SOLA
as a power supply is prohibited. The pump
contacts provided with the SOLA are for
controlling the pump only.
Fill the Boiler With Water
Adhere to the following:
1. Close combination shuto /purge valve in supply, all drain cocks, the
shuto valve for the pressure reducing ( ll) valve, and all manual air vents.
2. Close the isolation valves to the boiler.
3. Open all other system shuto valves and one of the zone valves, the vent
on the combination shuto /purge valve and the shuto valve to the
pressure-reducing ( ll) valve.
4. Water will now begin to ll the system. Air will escape through the vent
on the combination shuto / purge valve. Continue lling until a constant
stream of water (no bubbling) is discharged from the vent.
5. Close the zone valve on the purged loop, and open the zone valve on
the next loop to be purged. When all air has escaped and only water is
discharged, close the zone valve. When all zones have been purged (one at
a time), close the vent on the combination shuto /purge valve.
6. At this point, the system has been initially lled. However, air pockets
may still remain at high points in the system and in heating loops above
the level of the combination shut/o purge valve. It is quite possible,
depending on the particular system that all piping above the combination
shuto /purge valve still contains air. If manual vents are installed on the
system high points, these should be opened to vent these locations. When
only water is discharged from all vents, the initial purging is complete.
7. Open the combination shuto / purge valve (keep the vent closed). With
the gas shuto valve closed, turn on power to the boiler and operate the
circulator. Circulate the system water for approximately 30 minutes to
move all air to the automatic air separation point.
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, 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 o 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
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