FULTON Caliber - Table of Contents

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CAL-IOM-2012-1220 TABLE OF CONTENTS
0-1
Introduction 1-1
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Product Overview ................................................................................................. 2-2
Placement & Rigging ........................................................................................... 2-3
Clearances and Serviceability .............................................................................. 2-3
Install Boiler Trim ................................................................................................. 2-5
Install Water Piping .............................................................................................. 2-6
LOW WATER CUT OFF ...................................................................................................................27
Meet Water Chemistry Requirements ................................................................ 2-10
PREVENT FREEZING ...................................................................................................................211
PREVENT OXYGEN CONTAMINATION ........................................................................................211
ELIMINATE SYSTEM AIR ............................................................................................................211
Fill the Boiler With Water ................................................................................... 2-12
Install Gas Piping ............................................................................................... 2-13
Venting ............................................................................................................... 2-14
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................215
COMBUSTION AIR PIPED FROM OUTSIDE BUILDING WITHOUT SEALED COMBUSTION ........215
AIR PIPED FROM OUTSIDE BOILER ROOM ................................................................................215
Exhaust Venting .................................................................................................2-16
STANDARD VENTING CONFIGURATION, CATEGORY IV .............................................................216
SIZING AIR INTAKE AND EXHAUST PIPING ...............................................................................217
COMMON AIR INTAKE AND EXHAUST VENTING OF MULTIPLE BOILERS .................................218
INTAKE DUCT SIZING .................................................................................................................218
Condensate Drain Piping .................................................................................... 2-18
Venting Terminations ......................................................................................... 2-19
WALL THIMBLE INSTALLATION .................................................................................................220
HORIZONTAL VENT TERMINATION ............................................................................................221
Electrical Connections .......................................................................................2-22
Operation 3-1
Perform Pre-Start-Up Inspection ......................................................................... 3-2
Fill and Purge the System..................................................................................... 3-2
SOLA Control Program Presets ............................................................................. 3-2
Commission The Boiler ......................................................................................... 3-2
Test of Ignition Safety System .............................................................................. 3-3
Perform Test of Low Water Cut O ....................................................................... 3-3
Perform Test of Limit Controls ............................................................................. 3-3
Perform Test of Low Gas Pressure Switch ............................................................ 3-4
Perform Test of High Gas Pressure Switch ............................................................ 3-4
Perform Test of Air Switch .................................................................................... 3-4
Test of High Back Pressure Switch ........................................................................ 3-4
Normal Operation of the Boiler ............................................................................ 3-4
CHANGING THE OPERATING SET POINT .....................................................................................35
SETTING COMBUSTION ................................................................................................................36
Shut Down Procedures ......................................................................................... 3-7
NORMAL SHUT OFF PROCEDURES .............................................................................................37
EMERGENCY SHUT OFF PROCEDURES .......................................................................................37
SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME ........................................37
STARTING BOILER AFTER PROLONGED SHUTDOWN ..................................................................37
SOLA Control Features .......................................................................................... 3-8
VIEWING THE FLAME SIGNAL ....................................................................................................38
CYCLE AND RUN HOURS MONITORING .......................................................................................38
BOILER NAMING ..........................................................................................................................38
DELTA T LIMIT ...............................................................................................................................39
STACK LIMIT .................................................................................................................................39
LEAD/LAG CONFIGURATION .......................................................................................................39
MODBUS CONFIGURATION .......................................................................................................310
Maintenance 4-1
General ................................................................................................................. 4-2
Daily Maintenance and Inspection Schedule ...................................................... 4-2
Weekly Maintenance and Inspection Schedule .................................................. 4-2
Monthly Maintenance and Inspection Schedule ................................................. 4-2
Procedure for Cleaning the Air Inlet Filter .......................................................... 4-3
Relief Valve Testing ............................................................................................... 4-3
Annual Maintenance and Inspection Schedule ................................................... 4-3
EXAMINE THE VENTING SYSTEM ................................................................................................44
INSPECT HEATING SYSTEM FOR OTHER PROBLEMS ..................................................................44
Procedure for Removing/Cleaning The Burner .................................................... 4-4
Procedure for Cleaning Heat Exchanger ............................................................... 4-5
After All Repairs and Maintenance ...................................................................... 4-6
Troubleshooting ................................................................................................... 4-6
Warranty & Parts 5-1
Parts ..................................................................................................................... 5-2
Standard Warranty for Fulton Caliber Hydronic Boilers ....................................... 5-3