FULTON FHE-250 Installation, Operation & Maintenance Manual

FHE-250 MANUAL 09 2014 ISSUE 2

Fulton Ltd

FHE-250 Gas Fired
Condensing Boiler

250 kW

This Manual must be available to the boiler operator at all times.

INSTALLATION, OPERATION & MAINTENANCE

MANUAL

FHE-250 MANUAL 09 2014 ISSUE 2

The Pressure System Safety Regulations 2000

Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a ‘Competent Person’.
The scope of the examination and the actual intervals between examinations is at the discretion of the
competent person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the
system in which a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do
not cover periodic statutory inspections.

For further information contact:-

(a) SAFed
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.

(b) Health and Safety Executive local ofce.

(c) Your Competent Person.

For your Safety!

The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.

WARNINGS must be observed to prevent

serious injury or death to personnel.

CAUTIONS must be observed to prevent
damage or destruction of equipment or loss of
operating effectiveness.

NOTES: must be observed for essential and
effective operating procedures, conditions and
as a statement to be highlighted.

It is the responsibility and duty of all personnel
involved in the operation and maintenance of this
equipment to fully understand the WARNINGS,
CAUTIONS and NOTES by which hazards are to be
eliminated or reduced.

Personnel must become familiar with all aspects of
safety and equipment prior to operation or
maintenance of the equipment.

WARNING

Hot Water Boilers are a potential hazard, possibly fatal if not properly

maintained.

CAUTION

It is vitally important that the instructions

given in this manual are strictly adhered to.

Failure to carry out the routine maintenance

checks could result in a drastic reduction in the

life expectancy of the boiler.

CAUTION

Incase of Emergency

This boiler has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.

If such a condition should occur during commissioning or during subsequent operation of this product, what so
ever the cause, then the fuel supply to the boiler should be isolated immediately, until such time that the fault

has been investigated by a competent person and rectied.

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FHE-250 MANUAL 09 2014 ISSUE 2

LIST OF CONTENTS

INTRODUCTION 1

General 1.1
Technical Data 1.2
Optional Extras 1.3
Safety 1.4

- Safe Handling 1.4.1

- Safe Handling of Substances 1.4.2

INSTALLATION 2

General 2.1
Siting 2.2
Water Circulation System 2.3
Water Piping Installation 2.4
Water Treatment 2.5
Frost Protection 2.6
Preventing Oxygen Contamination 2.7
Eliminating System Air 2.8
Filling the Boiler with Water 2.9
Gas Supply 2.10

- Gas Connection 2.10.1
Sealed System Requirements 2.11
Ventilation 2.12

- Common Air Intake and Exhaust Venting of
Multiple Boilers

2.12.1

- Intake Duct Sizing 2.12.2
Exhaust Venting Terminations (Flues) 2.13

- Horizontal Exhaust Vent Termination 2.13.1
Flue Installation 2.14

- Flue System Design 2.14.1

- Flue Gas Conditions 2.14.2
Condensate Drain 2.15
Water and Gas Header Installation (Optional Extra) 2.16
Electrical Supply 2.17
Hydraulic Resistance 2.18
Electrical Connections 2.19

- External Wiring 2.19.1

- Terminal Connections for External Wiring 2.19.2

OPERATION 3

General 3.1
Perform Pre-Start-Up Inspection 3.2
Fill and Purge the System 3.3
Commissioning the Boiler 3.4

- Electrical Installation 3.4.1

- Gas Installation 3.4.2

- Flue Commissioning 3.4.3
Test of Ignition Safety System 3.5
Perform Test of Low Gas Pressure Switch 3.6
Test of Condensate Pressure Switch 3.7
Normal Operation of the Boiler 3.8

- Boiler Test Fire 3.8.1

- Disabling the Boiler 3.8.2

- Changing the Temperature Setpoint for DHW 3.8.3

- Changing the Temperature Setpoint for CH 3.8.4

- Finding the Master Boiler 3.8.5

- Boiler Operation 3.8.6

- Auto Detection 3.8.7
Shutdown Procedures 3.9

- Normal Shut off Procedures 3.9.1

- Emergency Shut off Procedures 3.9.2

- Shutting the Boiler Down for an Extended Period
of Time

3.9.3

- Starting the Boiler after Prolonged Shutdown 3.9.4
Display Operation 3.10
Symbols on the LCD 3.11
Push-buttons 3.12
Backlight 3.13
User Interface Operating Modes 3.14

- Initial Mode 3.14.1

- Standby Mode on Master DSP 3.14.2

- Standby Mode on Slave DSP 3.14.3

- Suspend Mode 3.14.4

- CH Setpoint Adjust Mode 3.14.5

- Auto Detection Mode 3.14.6

- Cascade Test Mode 3.14.7

- Local Test Mode 3.14.8

- Local Installer Mode 3.14.9

- History Mode 3.14.10

- Installer+ Mode 3.14.11

MAINTENANCE 4

General 4.1
Safety 4.2
Partial Isolation of Boilers in Cascade Systems 4.3
Servicing Schedule 4.4

- Daily 4.4.1

- Weekly 4.4.2

- Monthly 4.4.3

- Annual 4.4.4
Procedure for Cleaning the Air Inlet Filter 4.5
Examine the Flue System 4.6
Inspect Heating System for Other Problems 4.7
Procedure for Removing/Cleaning the Burner 4.8
Procedure for Cleaning the Heat Exchanger 4.9
Gas Valve Adjustment 4.10
After All Repairs and Maintenance 4.11
Handing Over 4.12
Error Codes and Troubleshooting 4.13
Maintenance Log 4.14

GENERAL DATA 5

Boiler Dimensions 5.1

Boiler Specication 5.2
Seasonal Efciencies 5.3

Recommended Water Conditions 5.4
Name Plates and Packaging Label 5.5

Electrical Diagrams (Supplied Separately)

FHE-250 MANUAL 09 2014 ISSUE 2

LIST OF CONTENTS

WARNING

Do not try to do repairs or any other maintenance work you
do not understand. Obtain a Service Manual from Fulton or

call a Fulton Service Engineer.

WARNING

It is the responsibility of the installer to ensure all parts

supplied with the boiler are tted in a correct and safe

manner.

WARNING

Understand the electrical circuit before connecting or

disconnecting an electrical component. A wrong connection

can cause injury and or damage.

WARNING

A defective boiler can injure you or others. Do not operate

a boiler which is defective or has missing parts. Make sure

that all maintenance procedures are completed before using

the boiler.

CAUTION

Obey all laws and local regulations which affect you and

your boiler.

WARNING

Do not change the boiler fuel without consulting the boiler

manufacturer.

WARNING

LIFTING EQUIPMENT

Make sure that lifting equipment complies with all local

regulations and is suitable for the job. You can be injured

if you use faulty lifting equipment. Make sure the lifting

equipment is in good condition.

WARNING

Operating the boiler beyond its design limits can damage

the boiler, it can also be dangerous.

Do not operate the boiler outside its limits.

Do not try to upgrade the boiler performance by unapproved

modications.

WARNING

Non-approved modications can cause injury and damage.

Contact your Fulton dealer before modifying the boiler.

WARNING

Only qualied persons should be allowed to operate and

maintain the boiler and its equipment. Boilers should always

be drained through an approved Blowdown Vessel.

WARNING

The installation of Gas appliances including the ue system

should only be carried out by Gas Safe Registered

Engineers.

CAUTION

HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and is

normally only required by engineering

surveyors / inspectors.
In order to ensure the material / pressure vessel does not
suffer from brittle fracture, hydraulic testing should not be

carried out below 7°C.

WARNING

DANGER FROM HOT SURFACES

Hot Water Boilers have high temperature surfaces, that if

touched may cause serious burns. Only competent and

qualied personnel should work on or in the locality of a

steam boiler and ancillary equipment. Always ensure the

working area and oor are clear of potential hazards, work

slowly and methodically.

Do NOT store inammable materials near the boiler.

WARNING

DANGER FROM INCOMPLETE COMBUSTION

The importance of correct burner adjustment to achieve low

emissions, safe, clean and efcient combustion is

paramount. Poor combustion, where unburnt gas forms
carbon monoxide is both a health hazard, and the potential
risk to the boiler from overheating, caused by re-burning of

the un-burnt gas in the secondary ue passes.

WARNING

The importance of correct boiler water and feedwater

cannot be over emphasised, see the relevant section in this

manual.

CAUTION

LOW FEEDWATER TEMPERATURE

Low feedwater temperature can result in thermal shock to

the boiler pressure vessel. Return the maximum amount of

condensate and if necessary pre-heat the feedwater. If in

doubt consult Fulton Ltd.

CAUTION

WATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners and

chemical treatment plants CAN BE SUPPLIED by Fulton.

It is the responsibility of the operator to ensure adequate

supplies of chemical are available at all times (including

commissioning).Costly repairs could be required should

the plant operate without chemicals or the wrong dosage of

chemicals.

SAFETY

The instructions provided for the operation and maintenance of the boiler MUST be observed.
Failure to do so could result in damage to the boiler and serious personal injury.

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FHE-250 MANUAL 09 2014 ISSUE 2

TITLE FIG. NO.

General Arrangement 1

General Arrangement with Panels Removed 2

Typical Gas Train 3

Flue Gas Conditions 4

Boiler Hydraulic Resistance 5

Boiler Communication Cables 6

Electrical Terminals 3-13 Disconnected 7

Jumper 8

Inserted Jumper Between Terminals 19 and 20 9

LCD Glass Layout 10

Push-button Layout 11

Boiler Dimensions 12

Name Plates 13

LIST OF ILLUSTRATIONS

FHE-250 MANUAL 09 2014 ISSUE 2

FIG.1 GENERAL ARRANGEMENT

Boiler Control
Panel

Adjustable Feet

FHE-250 MANUAL 09 2014 ISSUE 2

Page 1

1

The boilers are fully automatically controlled, oor standing and efcient condensing appliances.

The FHE-250 comprises of a single module capable of delivering 250 kW.

Up to 12 FHE-250 modules can be cascaded (for simplicity, only 250-1000 kW models are shown in
this manual), being stacked either vertically or horizontally.

The boiler controls built into the appliance include:

• Volt free ‘alarm’ contacts

• Burner hours run meters

• System temperature indication

The boilers can draw combustion air from the room or via ducting from outside.

Each module provides a maximum of 250 kW heat output and will modulate down to 41.66 kW
(see the table in Section 5.2 - Boiler Specication, for efciencies at different temperatures).
Boilers comprising of more than one module will share the heating load equally among modules,
switching modules off individually once the heating load drops below 16.67% of the total boiler

capacity. This way, a decreasing load is continuously matched for optimum efciency. The minimum

output from all models is 41.66 kW, providing a turndown ration of 6:1 for the 250 kW, 12:1 for the

500 kW, 18:1 for the 750 kW and 24:1 for the 1000 kW. Modules will re on the basis of least hours

run under the dictates of lead/lag sequencing from the onboard controller.

Each module includes a ap which only opens when the fan is running. This prevents energy wastage
when the boiler module is not ring.

The boilers are capable of high operating efciencies and low emissions (see Section 5) through

the combination of a sophisticated control system with premix burner and a stainless steel heat
exchanger.

These boilers are certied to meet the requirements of the EC Gas Appliance Directive, Boiler

Efciency Directive, EMC and Low Voltage Directive.

CAUTION

WATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners and chemical

treatment equipment CAN BE SUPPLIED by Fulton. It is the responsibility

of the operator to ensure adequate supplies of chemical are available at all times

(including commissioning). Costly repairs could be required should the plant operate

without chemicals or the wrong dosage of chemicals.

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SECTION 1 - INTRODUCTION

1.1

GENERAL

1.2

TECHNICAL DATA

For a full specication refer to Section 5.2 - Boiler Specication.

FHE-250 MANUAL 09 2014 ISSUE 2

Page 2

1

y Air Inlet Ducting Kit

For FHE-500 and above:

y Water and Gas Header Assembly - Packaged
y Water and Gas Header Assembly c/w Valves - Packaged
y Flue Header Kit

Note: Please contact Fulton Ltd for further details of all optional extras.

1.3

OPTIONAL EXTRAS

1.4

SAFETY

Current Gas Safety (Installation and Use) Regulations or rules in force.

The appliance is suitable for installation in any EU country and should be installed in accordance with

the rules in force.

In the UK, the installation must be carried out by a Gas Safe Registered Engineer or in IE by a
competent person. It must be carried out in accordance with the relevant requirements of the:

y Gas Safety (Installation and Use) Regulations

y The appropriate Building Regulations either The Building Regulations, The Building Regulations

(Scotland), Building Regulations (Northern Ireland).

y The Water Fittings Regulations or Water by-laws in Scotland.

y The Current I.E.E. Wiring Regulations.

Where no specic instructions are given, reference should be made to the relevant British Standard

Code of Practice.

In IE, the installation must be carried out by a Competent Person and installed in accordance with the
current edition of I.S.820:2000 “Non Domestic Gas Installations”, the current Building Regulations
and reference should be made to the current ETCI rules for electrical installation.

The boilers have been tested by a notied body and conform to EN656 and EN15417 for use with

Natural Gas. Detailed recommendations are contained in the following Standards and Codes of
Practice:

BS. 5854 Flue and ue Structures in Buildings.

BS. 6644 Installation of gas red hot water boilers of rated inputs between 70 kW and

1.8 MW (net) (2nd and 3rd family gases).

BS. 6880 Low temperature hot water heating systems of output greater than 45 kW.

Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.

IGE/UP/1 Soundness testing and purging of industrial and commercial gas installations.

IGE/UP/2 Gas installation pipework, boosters and compressors on industrial and

commercial premises.

IGE/UP/10 Installation of gas appliances in industrial and commercial premises.

FHE-250 MANUAL 09 2014 ISSUE 2

Page 3

1

The FHE-250 may require 2 or more operatives to move it to its installation site, and when moving

into its installation location. Manoeuvring the boiler will include the use of a pallet truck or forklift and
may involve pushing and pulling.

Caution should be exercised during these operations.

Operatives should be physically capable, and knowledgeable in handling techniques, when
performing these tasks. The following precautions should be reinforced:

y Be physically capable.

y Use personal protective equipment as appropriate, e.g. gloves, safety footwear.

During all manoeuvres, every attempt should be made to ensure the following:

y Keep back straight.

y Avoid twisting at the waist.

y Avoid upper body/top heavy bending.

y Always grip with the palm of the hand.

y Use designated hand holds.

y Keep load as close to the body as possible.

y Always use assistance if required.

1.4.1

SAFE HANDLING

1.4.2

SAFE HANDLING OF SUBSTANCES

No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture.

FHE-250 MANUAL 09 2014 ISSUE 2

Page 4

FIG. 2 GENERAL ARRANGEMENT WITH PANELS REMOVED

Venturi

Fan

Electrical Plate

Heat Exchanger

Return Pipe

Flow Pipe

Gas
Valve

Condensate

Pipe

Automatic

Air Vent

FHE-250 MANUAL 09 2014 ISSUE 2

Page 5

2

The installation of the FHE-250 Hot Water Boiler should be carried out by competent personnel in

accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that
these regulations are complied with.

WARNING

Maintenance on the burner assembly requires that the area directly in front of the boiler must

not be obstructed with pipework or equipment which would interfere with the removal of

the complete burner unit. Care should be taken on installation of the boiler to ensure this area

remains clear of obstructions.

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WARNING

Do not allow weight to bear on equipment components to prevent damage.

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SECTION 2 - INSTALLATION

2.1

GENERAL

2.2

SITING

(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1
Communication 1676, and in particular to Section 5, Location of Appliances).

The boiler house should be sufciently large to allow easy and safe access to all parts of the boiler

for operational and maintenance purposes.

1. The boiler must stand on a oor which must be at, non-combustible, level and of a suitable
load bearing capacity to support the weight of the boiler (when lled with water) and any
ancillary equipment.

2. The boiler must not be tted outside.

3. Install so that all system components are protected from water (dripping, spraying, rain etc)
during boiler operation and service.

4. Minimum clearance for access should be maintained at 600 mm at the front and at least one
side of the boiler/modular installation.

5. Ensure all labels on the boiler will be fully visible for maintenance and inspection.

FHE-250 MANUAL 09 2014 ISSUE 2

Page 6

2

A circulation pump MUST be connected to the boiler.

The boiler may be used for indirect hot water supply: wherever it is used for this type of system, an

additional heat exchanger must be provided to ensure hydraulic separation between primary and
secondary circuits.

Each boiler installation should incorporate a safety valve to ensure maximum pressure is not
exceeded.

The appliances are NOT suitable for gravity central heating nor gravity domestic hot water as system

pressure must be a minimum of 1 bar.

The boiler MUST be vented, there is an internal automatic air vent included for this purpose.

Draining taps MUST be located in accessible positions, which allow the draining of the whole
system - including the boiler and hot water storage vessel. They should be at least 1/2” BSP nominal
size and be in accordance with BS. 2879.

The central heating system should comply with the relevant standards on page 2.

Due to the compact nature of the boiler, the heat stored within the heat exchanger at the point of
shutdown of the burner must be dissipated into the water circuit in order to avoid overheating. To
allow pump operation after burner shutdown, the boiler control incorporates a pump overrun facility.
In order to make use of this, a pump must be controlled via the terminals inside the boiler.

When sizing pumps, reference should be made to hydraulic resistances given in Section 2.18, which

shows the boiler resistance against ow rates, to achieve the required temperature differential.

Flow rate using a 20°C temperature differential is 3.0 l/s (10.7 m³/hr) for each FHE-250
boiler/module.

The boilers MUST be installed in a closed loop system, it is the installers responsibility to ensure

adequate sized pressurisation units and expansion vessels are included for the system.

Note: With the boiler ring at maximum rate, the temperature differential should not be less than 20°C.

With the boiler ring at minimum rate, the temperature differential should not be greater than 35°C. Lower ow
rates generating higher temperature differentials will lead to poor system performance.

The lower the return temperature to the boiler, the higher the efciency. At return temperatures of 55°C and below,

the difference becomes marked because the water in the ue gases starts to condense, releasing its latent heat.

System designs should ensure the boiler minimum ow rates, as detailed in Section 5.2 - Boiler Specication,
are always maintained.

WARNING

If the water supply must be disconnected, the boilers must be turned off to prevent

accidental ue gas emission into the boiler room.

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2.3

WATER CIRCULATION SYSTEM

FHE-250 MANUAL 09 2014 ISSUE 2

Page 7

2

All water supplies contain some solids, dissolved gases or dissolved minerals. These may encourage

corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting boiler
performance, valve operation and general pipe longevity, each location must be analysed and treated
accordingly.

Adhere to the following for water piping installation.

1. The boiler requires a minimum temperature differential across the heat exchanger at high re,
and has a minimum ow requirement.

2. Ensure piping arrangements allow for heat-up times at or below 30 seconds; this will reduce
condensation which may contribute to equipment failure.

3. Pipe unions and isolation valves are recommended on both water connections for ease of
service.

4. Install piping so that the boiler is not supporting any additional piping.

5. The top water connection on the back of the boiler is the hot water inlet and must be connected
as the return from the system. The bottom connection is the ow/boiler outlet.

6. Install a hot water circulator, remote mounted from the boiler. Do not attach directly to the boiler.

7. 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 system shall be equipped with 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 FHE-250 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 should be completely 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.

WARNING

The boiler must be disconnected at the boiler shut off valve from the

gas supply piping system during any pressure testing of the system.

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CAUTION

Small levels of chlorides and/or sulphur presence in the combustion air or fuel will negatively impact

the heat exchanger components. Any presence of these contaminants will void the warranty.

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CAUTION

Some soaps used for leak testing are corrosive to certain types of metals. Rinse all piping thoroughly

with clean water after leak check has been completed.

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2.4

WATER PIPING INSTALLATION

FHE-250 MANUAL 09 2014 ISSUE 2

Page 8

2

These boilers incorporate a STAINLESS STEEL heat exchanger. For water conditions, please refer

to Section 5.4 - Recommended Water Conditions.

CAUTION

Heat exchanger failure due to inappropriate water quality, foreign matter or debris damage is not

covered under the warranty.

CAUTION

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.

CAUTION

The hydronic system should never be 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.

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Frost protection mode will be initialised when the boiler temperature sensor readings drop to 5°C.

The boilers will re until the water temperature reaches 15°C. Upon reaching 15°C the pumps will

continue to run for the pre-set duration of their overrun (specied by parameter “P 07” in Installer+

mode).

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WARNING

The application of any other treatment to this product other than those recommended by Fulton Ltd

may render the guarantee of Fulton Ltd invalid.

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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.

2.5

WATER TREATMENT

1. It is most important that the correct concentration of the water treatment products is maintained
in accordance with the manufacturers’ instructions.

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by
thorough cleansing.

3. In hard water areas, treatment to prevent limescale may be necessary.

4. Under no circumstances should the boiler be red before the system has been thoroughly

ushed.

2.6

FROST PROTECTION

2.7

PREVENTING OXYGEN CONTAMINATION

1. There are several ways to prevent boiler water oxygen contamination:

2. Minimise system leaks to minimise make up water requirement

3. Do not use open tanks or ttings

4. Do not use oxygen permeable materials anywhere in the water system

5. Repair leaks in the system quickly

6. Eliminate ttings wherever possible

FHE-250 MANUAL 09 2014 ISSUE 2

Page 9

2

There is a factory-installed AAV (automatic air vent) on the heat exchanger.
The AAV must not be altered or removed.

The local gas supplier should be consulted at the installation planning stage in order to establish

the availability of an adequate supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.

A gas meter can only be connected by the local gas supplier, in UK by a Gas Safe Registered

Engineer or in IE by a competent person.

An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is

adequate to deal with the dynamic rate of gas supply required. A minimum working gas pressure of

6.5 mbar MUST be available at the boiler inlet for Natural Gas.

Do not use pipes of a smaller size than the boiler inlet gas connection.

The complete installation MUST be tested for gas soundness and purged in accordance with the

appropriate standards.

Gas Boosters

A gas booster is required if the gas pressure available at the boiler is lower than 6.5 mbar. Boosted

gas supplies should not exceed 20 mbar.
Location of the booster requires careful consideration but should preferably be closer to the burner
rather than the gas meter. Ventilation should also be considered to ensure ambient temperatures do
not exceed designed recommendations. Further guidance is provided in IGEM/UP/2 (Institution of
Gas Engineers and Managers-Installation pipework on industrial and commercial premises.
Communication number 1729).

2.8

ELIMINATING SYSTEM AIR

2.9

FILLING THE BOILER WITH WATER

2.10

GAS SUPPLY

Adhere to the following:

1. Once the boilers have been installed and connected to the distribution system, open the
isolating valves on each boiler, the AAV’s (automatic air vents) will vent any excess air in the
system.

2. Visually inspect all pipe joints and equipment connections for leaks. If necessary, drain system,

repair leaks and rell/purge the system. If no pressure drop is detected for a period of two hours

under pressure, the system may be considered watertight.

3. When purging is completed, make sure the following are open: combination shut-off/purge valve,

shutoff valve to pressure reducing (ll valve), shutoff valve in cold water ll line, and shutoff

valve in return line.

4. Make sure the following are closed: all drain cocks, the vent on the combination shutoff purge
valve, and all manual vents.

5. Open fuel shut-off valve, allowing fuel to ow to boiler.

FHE-250 MANUAL 09 2014 ISSUE 2

Page 10

2

WARNING

Do not use any source of ignition to check for gas leaks

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CAUTION

Some soap used for leak testing is corrosive to certain types of metals.

Clean all piping thoroughly after completing the leak check.

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CAUTION

Never leave an opened manual air vent unattended.

In the event that an opened vent is left unattended, water damage could occur.

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CAUTION

The presence of chlorides and/or sulphur in the combustion air or fuel

will negatively impact the heat exchanger and void the warranty.

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The gas supply pipe terminates in a 28 mm copper pipe connection on each 250 model. Common

gas supply pipe sizes for connection to multiple boiler modules are available on request from Fulton.

1. A minimum working gas pressure of 6.5 mbar must be available at the boiler inlet with the

boiler ring.

2. Fit a gas supply pipe at an appropriate size in order to limit the pressure drop between the
meter outlet and connection to the boiler(s) to 1 mbar (100 Pa) max.

3. All gas supply pipework must be independently supported.

4. The boiler and all gas piping connections must be pressure-tested and checked for leaks
before being placed into service. Test with compressed air or inert gas if possible.

5. The boiler must be disconnected at the boiler manual shutoff valve (located near the end of
the supplied gas train at the front of the boiler) from the gas supply piping system during any
pressure testing of the system at pressures in excess of 35 mbar (3.5 Pa).

6. Gas piping must be installed in accordance with all relevant gas codes and any other local
codes which may apply.

7. The pipe and the ttings used must be new and free of dirt or other deposits.

8. After gas piping is completed and before wiring installation is started, carefully check all

piping connections, (factory and eld), for gas leaks. Use a soap and water solution.

2.10.1

GAS CONNECTION

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FIG. 3 TYPICAL GAS TRAIN

Modulating
Gas Valve

Inlet to
Modulating
Gas Valve

Isolating
Valve

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Working pressure 6 bar maximum, 1 bar minimum.

Particular reference should be made to BS. 6644, Guidance note BG01 “Guidance on safe operation
of boilers” and “INDG436 “Safe management of industrial steam and hot water boilers”, published by
the Health and Safety Executive.

The information and guidance given below is not intended to override any requirements of either of

the above publications or the requirements of the local authority, gas or water undertakings.

In general commercial closed pressurised systems are provided with either manual or automatic
water make up.

In both instances it will be necessary to t automatic controls intended to protect the boiler, circulating
system and ancillary equipment by shutting down the boiler plant if a potentially hazardous situation
should arise.

Examples of such situations are low water level and operating pressure or excessive pressure within the
system. Depending on circumstances, controls will need to be either manual or automatic reset. In
the event of a shutdown both visual and audible alarms may be necessary.

Expansion vessels used must comply with EN 13831 and must be sized on the basis of the total
system volume and initial charge pressure.

Initial minimum charge pressure should not be less than 1.0 bar (100 kPa) and must take account of

the static head and specication of the pressurising equipment.

When make up water is not provided automatically it will be necessary to t controls which shut down

the plant in the event of the maximum system pressure approaching to within 0.35 bar (35 kPa) of
the safety valve setting. Other British Standards applicable to commercial sealed systems are:
BS. 6880: Part 2 BS. 1212 BS. 6281: Part 1 BS. 6282: Part 1 BS. 6283: Part 4

2.11

SEALED SYSTEM REQUIREMENTS

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Adequate fresh, clean air is necessary for safe and efcient combustion, and should be provided at

high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part 1 Communication 1676.

Note:

a) Ensure there is adequate ventilation in the boiler room. Lack of ventilation will create a high temperature and

cause control lockout.

b) Where mechanical ventilation is provided for plantrooms, ensure positive pressurisation of the space is

always maintained - hazardous interlock with the boiler may be required for this purpose.

c) Do not store chemicals such as perclorethylene in the boiler house, the fumes may damage the boiler and

ue and cause the burner to lock out on ame failure. The ventilation requirements of these boilers are
dependant on the type of ue system used, and their heat input. All vents must be permanent with no means

of closing, and positioned to avoid accidental

obstructions by blocking or ooding.

Detail reference should be made to BS. 6644 for inputs between 70 kW and 1.8 MW (net).

In IE refer to the current edition of I.S.820:2000. The following notes are for general guidance only:

Dust contamination in the combustion air may cause blockage of the burner slots. Unless the boiler room
provides a dust free environment then direct connection of the air intake via ducting to clean outside
air should be used.

IMPORTANT NOTE: If combustion air is drawn from within the boiler room, ensure no dust or airborne debris can
be ingested into the appliance. Dusty concrete ooring should be sealed to reduce the presence of dust.

The temperature within a boiler room shall not exceed 25°C within 100 mm of the oor, 32°C at mid

height and 40°C within 100 mm of the ceiling.

Open Flued Installations

If ventilation is to be provided by means of permanent high and low vents communicating direct with
outside air, then reference can be made to the sizes below. For other ventilation options refer to BS.

6644. In IE refer to the current edition of I.S.820.

Required area (cm2) per kW of total rated input (net)

Note: Where a boiler installation is to operate in summer months (e.g. DHW), additional ventilation requirements

are stated within BS6644 if operating for more than 50% of the time.

Boiler Room Enclosure

Low Level (Inlet) 4 10

High Level (Outlet) 2 5

2.12

VENTILATION

Required area (cm2)

Boiler Room

FHE-250 FHE-500 FHE-750 FHE-1000

Low Level (Inlet) 1020.4 2040.8 3061.2 4081.6

High Level (Outlet) 510.2 1020.4 1530.6 2040.8

Enclosure

FHE-250 FHE-500 FHE-750 FHE-1000

Low Level (Inlet) 2551 5102 7653 10204

High Level (Outlet) 1275.5 2551 3826.5 5102

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Combining multiple FHE-250 boilers into a common ue or duct for combustion air supply,

exhaust, or both is only permitted on a case by case basis and must be accomplished with an
engineered solution. Please contact Fulton for details/designs.

Adhere to the following:

1. There is an integral combustion air supply damper within the unit, complete with a magnetic

switch that is fully integrated into the standard boiler controls, to prevent ue gases from
entering the plantroom.

2. FHE-250 boilers should not be common vented with other types of equipment.

WARNING

Fulton cannot assume responsibility for an air intake or exhaust

arrangement where FHE-250 boilers are common vented with any other type of equipment.

!

1. Air intake ducting must be sized in conjunction with the exhaust venting to provide no greater

than a 2 mbar (200 Pa) combined pressure drop. Refer to Section 2.14.1 - Flue System
Design for further details and guidance on this issue.

2. Each FHE-250 module with internal intake ducting incorporates a coarse air lter. The
installation of a recognised termination screen is required on all combined air intakes for
multiple boiler modules.

3. Air intake ducts and ttings shall be galvanised steel or Schedule 30 PVC pipe.

Note: where these boilers are to be room-sealed,the internal air inlet ductwork and ttings and external connector

for ducted connections are all in galvanised steel.

4. If using PVC, all intake PVC piping must be assembled using suitable cement. This will
ensure that the intake is airtight and will not allow contaminants from the boiler room into the

boiler.

5. Air intake terminations must be suitably weatherproofed to prevent ingress of moisture into
the system.

2.12.1

COMMON AIR INTAKE AND EXHAUST VENTING OF MULTIPLE BOILERS

2.12.2

INTAKE DUCT SIZING

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Adhere to the following for installation:

1. All vents and ttings must be installed with a minimum of 100 mm air space clearances to

combustibles. These air space clearances apply to indoor or outdoor vents-whether they are

open, enclosed, horizontal or vertical or pass through oors, walls, roofs or framed spaces. The
air space clearances should be observed to joists, studs, suboors, plywood, drywall or plaster

enclosures, insulating sheathing, rafters, roong, and any other material classed as combustible.

2. The required minimum air space clearances also apply to electrical wires and any kind of
building insulation.

3. Adequate provision must be made to support the weight of the exhaust venting. It cannot be
supported by the boiler exhaust connection.

4. Terminations must be adequately weatherproofed.

WARNING

Assure all electrical connections are powered down prior to attempting replacement or service of

electrical components or connections of the boiler.

!

2.13

EXHAUST VENTING TERMINATIONS (FLUES)

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IMPORTANT NOTE: Wherever horizontal runs of exhaust vents are installed, a minimum slope of 1:50 must be
maintained, falling back toward the boiler(s).

Adhere to the following for installation:

1. Where the vent termination is joined to the vent pipe outside the wall. Use the same joining

procedures for vent pipe and ttings. The termination of the vent system must be at least
305 mm above the nished grade, or at least 305 mm above normal snow accumulation

level (for applicable geographical areas). The termination of the vent system should not be

located in trafc areas such as walkways, adjacent buildings, openable windows and building
openings unless the venting system is at least 21.3 m above nished grade. The vent

terminations must be at least 1.22 m horizontally from electric meters, gas meters,
regulators, and relief equipment.

2. When installing inlet and exhaust terminations on the same wall, the exhaust outlet must be

installed 0.914 m minimum above and downwind from air supply inlet to prevent exhaust

recirculation. Under certain wind conditions, some building materials may be affected by ue

products expelled in close proximity to unprotected surfaces. Sealing or shielding of the
exposed surfaces with a corrosion resistant material may be required to prevent staining or
deterioration.

3. The minimum vent height should extend to at least 0.914 m above the roof, or at least

0.609 m above the highest part of any structure within 3.04 m of the vent.

4. If the exhaust vent terminates within 3.04 m horizontally of the air inlet, the exhaust vent

must be at least 1.22 m above the inlet. Dimensions listed above and those illustrated are
minimum, and may or may not be sufcient for conditions at a specic job site.

5. To prevent the possible re-circulation of ue gases,the vent designer must take into

consideration factors such as prevailing winds, eddy zones, building congurations,
etc. Fulton cannot be responsible for the effects such adverse conditions may have on the
operation of the boilers. It is important to locate the exhaust duct in such a way that it does
not become blocked due to snow, ice, and other natural or man-made obstructions.

2.13.1

HORIZONTAL EXHAUST VENT TERMINATION

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IMPORTANT NOTE: It is the responsibility of the installer to ensure, in practice, that products of combustion
discharging from the terminal cannot re-enter the building or any other adjacent building through ventilators,
windows, doors, other sources of natural air inltration, or forced ventilation / air conditioning.

If this should occur the appliance MUST be isolated from the gas supply and labelled as ‘unsafe’ until corrective

action can be taken.

Terminal Position

Due to the high efciency of the boilers pluming will occur.

Particular care should be taken in the case of large output boiler installations, and ensuring that
in the UK they comply with the requirements of the Clean Air Act.

The ue must be installed in accordance with the appropriate Building Regulations and standards

listed on page 4 and in compliance with BS6644. In IE refer to I.S.820:2000.

2.14

FLUE INSTALLATION

2.14.1

FLUE SYSTEM DESIGN

Due to the high efciency of these boilers, the ue gas temperatures are low and the buoyancy in

the stack will be relatively small. The boiler is supplied with an integral fan which is fully matched

to the boiler in each case to provide correct combustion air ow and overcome the ue resistance.

The power of this fan is such that there is a large reserve of pressure available to overcome a

signicant length of ue without affecting the combustion performance of the boiler.

The maximum pressure available at the base of the ue to overcome ue resistance is 2.5 mbar
(250 Pa.) This gure should be reduced to 2 mbar (200 Pa) if the boiler is to be room sealed and
incorporates a combustion air inlet duct. Care should be taken with tall ue systems to ensure
excess buoyancy is not created. A negative pressure must not be created at the boiler ue outlet.

Refer to the tabulated data at the end of this section for ue and duct pressure losses.

IMPORTANT NOTE: If combustion air is drawn from within the boiler room, ensure no dust or airborne debris can
be ingested into the appliance. Dusty concrete ooring should be sealed to reduce the presence of dust. Ideally
where possible duct the air supply into the boiler room from a clean source outside the boiler room / building.

Material

With no requirement for buoyancy to discharge ue products and with low ue gas temperatures,
single wall ues are suitable for most installations. Care should still be taken to maintain

compliance with building regulations and relevant standards.

The ue used should be a suitably approved ue for use on a pressurised condensing ue
system. The boiler is not suitable for use on plastic ue systems.

Condensate produced in the ue should be drained separately.

Advice regarding the availability of proprietary types of ue system can be obtained by contacting

Fulton.

All joints or connections in the ue system must be impervious to condensate leakage. Low points
in the ue system should be drained using pipe of material resistant to condensate corrosion.

All drains in the ue should incorporate a water trap.

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Note: Long Flues: It is recommended that a support bracket is tted at least every 1 m of ue length and a
bracket must be tted at every ue joint to ensure ue seal and alignment of ue.

WARNING

Care should also be taken in the selection of ue terminals as these tend to accentuate the formation

of a plume and could freeze in cold weather conditions.

WARNING

Care should be taken to ensure the specication of the chimney is suitable for the application by

reference to the manufacturers literature.

WARNING

Where single walled ues are used on the appliance, surface temperatures of the ue can reach

temperatures in excess of 80°C.

!

!

!

Flue/Exhaust Vent

Item

Size

(mm Ø)

Pressure Drop

(Pa)

1 m of Flue/Vent 150 0.33

45 Degree Bend* 150 1.72

90 Degree Bend* 150 3.44

* All bends on Flue/Exhaust Vent systems should be
long radius.

Inlet Duct/Pipe (For room sealed boilers only)

Item

Size

(mmØ)

Pressure Drop

(Pa)

1 m of Duct/Pipe 100 0.35

45 Degree Bend 100 0.19

90 Degree Bend 100 0.49

1 m of Duct/Pipe 80 1.00

45 Degree Bend 80 0.47

90 Degree Bend 80 1.18

2.14.2

FLUE GAS CONDITIONS

Following installation of the ue(s) for the boiler, and set-up/commissioning of the burner, the following
should be used as a guide for the ue gas content and temperature.

For further details of the boiler set-up and commissioning, refer to section 3 of this manual.

Flue Gas Constituents

Item %

Carbon Dioxide (CO

2

) 9.5 ± 2.5

Carbon Monoxide (CO) 0.0075 ± 0.0075

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Condensate drains are provided on the boiler. These drains must be connected to a drainage point

on site. All pipework and ttings in the condensate drainage system MUST be made of plastic - no

other materials may be used.

Each module is provided with a condensate trap, the pipe size from the trap outlet is 22 mm.
The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler,
throughout its length.

Connect a condensate drain to each outlet and pipe to a suitable drain point preferably within the
building.

IMPORTANT NOTE: Any external runs must be kept to a minimum and insulated to avoid freezing in cold weather

causing blocking.

2.15

CONDENSATE DRAIN

2.16

WATER AND GAS HEADER INSTALLATION (OPTIONAL EXTRA)

Water and gas header systems can be supplied as fully assembled self supporting units capable of
connecting the water and gas services direct to the rear of the module/s. Each header system
will be individually tailored to specic site/installation requirements. This is an optional extra, as
detailed in Section 1.3, please contact Fulton for further details/designs.

FIG. 4 FLUE GAS CONDITIONS

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Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS7671) Wiring
Regulations and any local regulations which apply. For Ireland reference should be made to the
current ETCI rules for electrical installations.

The point of isolation from the mains should be readily accessible and adjacent to the boiler.

!

WARNING

This appliance must be earthed.

Pressure Drop (kPa) Flow Rate (L/s)

4.31 0.83

15.67 1.67

30.39 2.43

44.12 3

FIG. 5 BOILER HYDRAULIC RESISTANCE

2.17

ELECTRICAL SUPPLY

2.18

HYDRAULIC RESISTANCE

The hydraulic resistance through each FHE-250 module is 441 mbar (44.12 kPa) at full duty

conditions, with a 20°C temperature differential between inlet (return) and outlet (ow).

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A mains supply of 230 V 50 Hz is required (Live, Neutral and Earth). An additional Earth is required to be

connected to the Master Module chassis Earth Bonding point on the front RHS vertical frame strut.

Where more than one module is to be installed, i.e. FHE-500, 750, 1000 each module chassis must
also be bonded together using earth bonding straps.

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS7671) wiring
Regulations and any local regulations. For Ireland reference should be made to the current ETCI
rules for electrical installations.
Connection should be made in a way that allows complete isolation of the electrical supply- such as
a double pole switch, having a 3 mm (1/8”) contact separation in both poles. The means of isolation
must be accessible to the user after installation.

When making mains electrical connections to the modules it is important that the wires are prepared
in such a way that the earth conductor is longer than the current carrying conductors, such that if
the cord anchorage should slip, the current carrying conductors become taut before the earthing
conductor.

!

WARNING

This appliance MUST be earthed.

!

WARNING

Sensor cables must be separated from cables in the 230 V circuit.

External wiring MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations.
For Ireland reference should be made to the current ETCI rules for electrical installations.

For wiring external controls to the boiler, reference should be made to the systems wiring diagram
supplied by the relevant manufacturer.

Difculty in wiring should not arise, providing the following directions are observed:

All cables should be secured using cable glands in locations through the boiler panels to suit the
individual arrangements.

Note: Care should be taken when positioning the holes for the wiring to ensure no clashes with any of the internal

structure of the boiler or the on-board electrical panel. All external devices should be wired to each boiler in the
same way.

1. The appliance must be wired with a permanent live supply. External controls should NOT be
wired in series with this mains input. Controlling the mains input in this way will prevent the
pump over-run sequence and may cause damage to the heat exchanger.

2. Connection of Header Pump: A Cascade/System pump may be connected to the
boilers via an external contact or relay with options for single speed pump (volt free
contact - On/Off) or variable speed PWM (Pulse Width Modulation) pump. This pump is
controlled from the boiler and runs whenever any module is active, also providing pump
overrun. This output may also be used to provide pump overrun requirements to a BMS or
control panel where multiple pumps or zones are installed. For details of the terminal
connections to use for the different pump types, refer to the tables in Section 2.19.2 of this
manual.

Note. The circuit protective device, isolation switch and wiring must be sized in accordance with the total load of

both the boiler and module pumps.

2.19

ELECTRICAL CONNECTIONS

2.19.1

EXTERNAL WIRING

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Heat Demand

1. A thermostat (or a volt free contact) can be wired into screw terminals for CH and/or DHW as
applicable to the installation.

2. An external controller with OpenTherm communication port can be wired into the boilers. In this
case the controller will generate the required setpoint for CH only. This needs to be wired

parallel to all of the boilers. Please nd the supported OpenTherm system messages in the

table below.

Master

Boiler

Slave 1

Boiler

Slave 2

Boiler

Slave 3

Boiler

15

14

17

16

19

18

20

15

14

17

16

19

18

20

15

14

17

16

19

18

20

15

14

17

16

19

18

20

ID Read/Write Description

0 R Status

1 W Control Setpoint

5 R Fault ags/code

2 W Master Conguration (dummy write)

3 R Slave Conguration

4 W Lockout Reset

17 R Relative Modulation Level

25 R CH Water Temperature

For details of the terminal connections to use for the thermostat(s) and OpenTherm controller, refer
to the tables in Section 2.19.2 of this manual.

Cascade Temperature Sensor (Header Sensor)

A cascade temperature sensor is provided to monitor the desired set point temperature to

control the boiler outputs. This needs to be placed after the boiler header at an appropriate point in

the system ow pipework.

The sensor needs to be wired in parallel to all of the boilers.

Boiler Status Signals

A normally open volts free contact is provided to indicate a fault of the boiler to remote system

controls. Please refer to the tables in Section 2.19.2 - Terminal Connections for External Wiring.

Boiler Communication Cables

The gure below shows the wire connections between the boilers in a cascade system.

* Link Terminal 19 and 20

FIG. 6 BOILER COMMUNICATION CABLES

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2.19.2

TERMINAL CONNECTIONS FOR EXTERNAL WIRING

HIGH VOLTAGE TERMINALS

TERMINAL DESCRIPTION

1 Live Supply 240 Vac, max. 3.2 A

2 Neutral

3

29

CH pump neutral
CH pump live, 240 Vac, max. 0.8 A

4

30

DHW 3 way valve neutral
DHW 3 way valve live, 240 Vac, max. 0.8 A

5

31

CH 3 way valve or DHW water pump neutral
CH 3 way valve or DHW water pump live, 240 Vac, max. 0.8 A

25 and 26 Common alarm volt free contact, 240 Vac, max 5 A resistive load

27 and 28 Cascade pump On/Off contact, 240 Vac, max 5 A resistive load or 0.5 A inductive

LOW VOLTAGE TERMINALS

TERMINAL DESCRIPTION

6

21

DHW sensor/volt free switch (DHW demand) neutral
DHW sensor/volt free switch (DHW demand) live, max. 30 V

7 and 8 Cascade pump PWM outputs (variable speed)

9 and 10 OpenTherm communication port

11 and 23 External temperature sensor, RTD 10 kΩ @ 25 ˚C

12 and 24 Cascade temperature sensor, RTD 12 kΩ @ 25 ˚C

13
22

CH demand neutral
CH demand live, max. 30 V

14 and 15 Terminal 14 on the Boiler connects to Terminal 15 on the following Boiler in line

16 and 17 Terminal 16 on the Boiler connects to Terminal 17 on the following Boiler in line

18 and 19 Terminal 18 on the Boiler connects to Terminal 19 on the following Boiler in line

20 Terminal 20 on the boiler needs to be linked to Terminal 19 on the slave boiler*

* Refer to Fig.6, Page 22

Boiler Terminal Plugs

The following terminal plugs need to be disconnected for the boilers to operate correctly:

Master Boiler: None

Slave in between other boilers: Terminals 3 to 13 and Terminal 20

Last Slave Boiler: Terminals 3 to 13 and Terminal 19

Note: Plugs do not need to be fully removed to be electrically disconnected. The terminal plugs have two
positions: electrically disconnected and connected.

Fig. 7 shows electrical Terminal plugs 3-13 disconnected, while other terminals are electrically connected. Note
that it is possible to remove the plugs, but not necessary for isolation.

Fig. 9 shows a jumper inserted between Terminal 19 and 20.

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2

FIG. 7 ELECTRICAL TERMINALS 3-13 DISCONNECTED

FIG. 8 JUMPER

FIG. 9 INSERTED JUMPER BETWEEN TERMINALS 19 AND 20

Inserted

jumper

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3

The following instructions are given for the guidance of the operator in the use of the FHE-250 boiler

and to provide adequate information to ensure that the boiler is used safely and without risk to
health. Where original equipment Service Manuals are supplied, they must be read and understood
in conjunction with this manual. All warnings and cautions MUST be observed.

WARNING

Use only your hand to turn the valve handle. Never use tools. If the knob will not turn by hand, do not try

to repair it. Call a qualied service technician. Force or attempted repair may result in a re or explosion.

!

WARNING

This boiler is equipped with an ignition device, which automatically lights the burner.

Do not try to light the burner by hand.

!

WARNING

Do not store or use gasoline or other ammable vapours and liquids in

the vicinity of this or any other appliances.

!

WARNING

Do not attempt to start the boiler for any testing before lling and purging the boiler. A dry re will

damage the boiler and may result in property damage or personnel injury, which is not covered by the

warranty.

!

SECTION 3 - OPERATION

3.1

GENERAL

3.2

PERFORM PRE-START-UP INSPECTION

Prior to start-up, perform the following:

1. Smell all around the boiler area for gas. Be sure to smell next to the oor, as some gas is

heavier than air and will settle. If you smell gas:

- Do not try to light any appliance.

- Do not touch any electrical switch; do not use any phone in your building.

- Immediately call your gas supplier from a safe location outside of the property.

2. Ensure the boiler is located with the proper clearances. A minimum of 600 mm should be

allowed for at the front of each FHE-250 unit. Please contact Fulton for clearances required for
modular installations.

3. Ensure that relief valves where tted, have been properly piped to oor drains.

4. Ensure ue gas from the boiler is properly vented.

5. Ensure the water system has been ushed and is free of debris.

6. Ensure combustion air openings are not obstructed in any way and have adequate capacity.

7. Ensure there are no ammable liquids, materials or hazardous fumes present in the

environment.

8. Ensure nothing was damaged or knocked loose during installation and/or shipment, including

main gas train and trim assembly.

3.3

FILL AND PURGE THE SYSTEM

Refer to Section 2.9 - Filling the Boiler with Water for procedure. Attempting to start the boiler

prior to Fill and Purge may result in dry re, which can cause injury or property damage, and is not

covered by warranty.

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3

It is essential that the commissioning procedures listed below are carried out either by a
Fulton Service Engineer or by an authorised professional who will have the necessary experience
and testing equipment to ensure that the installation is not only correct, but is operating safely and

at optimum efciency.

1. Verify with authorised personnel that the gas lines have been purged. Do not proceed without

verication.

2. Familiarise all personnel on all aspects of boiler use, safety, and contents of this manual. This

includes, but is not limited to, the use of the controls, lighting/ring the boiler, and shutdown

procedures.

3. Review the unit-specic control schematics, and follow appropriate instructions.

WARNING

Before commissioning the boiler, verify with authorised personnel that the gas lines have been purged.

!

WARNING

Commissioning/Start up by a non-Fulton authorised person will void the product warranty.

!

!

WARNING

Whilst effecting the required gas soundness test and purging air from the gas installation, open all

windows and doors, extinguish naked lights and DO NOT SMOKE.

1. The whole of the gas installation, including the meter, should be inspected and tested for
soundness and then purged in accordance with the recommendations of the relevant standards
listed on Page 2. In IE refer to I.S.820:2000.

3.4

COMMISSIONING THE BOILER

3.4.1

ELECTRICAL INSTALLATION

3.4.2

GAS INSTALLATION

3.4.3

FLUE COMMISSIONING

1. Check to ensure electrical safety should be carried out by a competent person.

2. ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity,

resistance to earth using a suitable meter.

Prior to initial ring of the boiler, the ue must be checked for leaks.

This is done by BOTH of the following methods:

Visual Inspection

Check joints between all ue sections for quality of seals. Where the ue passes through the structure
of the building use your judgement as to the integrity of this section of the ue.

Smoke Test

With the ue capped, the drain stabiliser pipe (if tted) blanked and a smoke generator inserted into
the ue, there should be no smoke visible from the ue.

If either of these tests fail or at any time during boiler operation there is doubt about the integrity of

the ue, shut down the boiler and contact Fulton Ltd immediately.

Note: Flues that are designed to operate with positive pressure should be tested to the latest regulations.

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3

Test the ignition system safety shutoff as follows:

1. Disconnect the boiler from the mains power supply.

2. Remove the grey plug/connector from the main gas valve (it is held on with a central screw).

3. Re-connect the boiler to the mains power supply.

4. With the main gas cock (inlet manual gas valve) open, the burner should be cycled on. After all

the safety limits such as gas pressure and temperature are satised, the blower will run and

pre-purge the boiler.

5. Once the purge is complete (5 seconds), the ignition transformer will be energised. There will be
a 4 second trial for ignition period.

6. The main gas valve will not open because there is no power to the valve due to the

disconnected wires. Hence, no ame will be established and the ame safeguard will not

receive a ame signal from the ionisation probe.

7. After 4 seconds, the ame safeguard programmer will assume a “Flame Failure” condition and
limits the boiler. Limiter will not require manual reset of the ame safeguard. The control will

allow three retries before limiting.

8. After completing this test, turn off the boiler and reconnect the plug to the main gas valve,
ensuring the boiler is disconnected from the mains power supply prior to reconnecting the gas
valve plug.

3.5

TEST OF IGNTION SAFETY SYSTEM

3.6

PERFORM TEST OF LOW GAS PRESSURE SWITCH

Test the low gas pressure switch as follows:

1. Turn off the gas cock, then start the boiler until a limiter is annunciated- Error code: E76.

2. Re-open the gas cock, restart the boiler.

H

Fire the boiler and test the condensate pressure switch as follows:

1. Remove the cover plate from the switch. At high re turn the adjustment on the switch counter

clockwise (reducing the switch set-point to below the 9 mbar factory setting) until the boiler
shuts down. Error code: E77.

2. Reset the switch to the factory setting of 9 mbar.

3.7

TEST OF CONDENSATE PRESSURE SWITCH

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3.8

NORMAL OPERATION OF THE BOILER

Under normal operating circumstances, this boiler functions as a fully automatic appliance. The

automatic control senses the water outlet temperature and res the boiler when heat is needed by

the system. Additionally this boiler may function as part of an integrated building management

system. Outlet water temperature is shown on the display, on the front of the boiler.

3.8.1

BOILER TEST FIRE

There are two ways of testing the boiler; individually or all together (where there is more than one

boiler module included in an installation) – also called a cascade test. To complete the boiler test re,

proceed as follows:

1. Local Test

a) Switch on the boiler, if there is an error message, resolve the error rst- Refer to

Section 4.13 - Error Codes And Troubleshooting. Once any errors are resolved proceed
to the next step.

b) Press and hold the “Test Mode” button for 3 seconds on the boiler to be tested.

c) The display will show “t 0”, this represents approximately 20% of the maximum output.

d) Push the “DHW +” button to instantly bring the boiler up to maximum ring rate. The display

now shows “t 100”, this represents 100% output. Pushing “DHW –” will bring it back to the
minimum ring rate.

e) Pushing the “CH +” and “CH –” buttons will adjust the boiler output in increments of 1%.

f) Press and hold the “Test Mode” button for 3 seconds to exit the Local Test mode.

2. Cascade Test

a) Switch on the boiler, if there is an error message, resolve the error rst – Refer to

Section 4.13 - Error Codes And Troubleshooting. Once any errors are resolved proceed
to the next step.

b) Press and hold the “Test Mode” and “Conrm” buttons for 3 seconds on the master boiler.

c) Adjust the ring rate as explained in the Local Test procedure above.

d) Press and hold the “Test Mode” and “Conrm” buttons for 3 seconds to exit the Cascade

Test mode.

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There are three ways that the boiler can be disabled without shutting down the whole system:

1. Press the “DHW Mode” button. Safety procedures and frost protection are still active, but the

boiler will not re on DHW demand. To exit, press the “DHW Mode” button again.

2. Press the “CH Mode” and “DHW Mode” buttons together to enter Suspend mode. Only frost
protection is active in Suspend mode. To exit Suspend mode, press the “Conrm” button once.

3. If the DHW demand is controlled by a switch, move the switch into the “Off” position to stop the
boiler. This will stop the boiler until the switch is turned back to the “On” position.

Note: Frost protection will be active at all times as long as the boilers are not disconnected from the power supply
and they are not in error mode. Any boiler that is in error mode will not re until the error condition ceases.

3.8.2

DISABLING THE BOILER

3.8.3

CHANGING THE TEMPERATURE SETPOINT FOR DHW

1. Go into Installer+ mode by pressing the “Conrm” and “DHW Mode” buttons for 3 seconds.

2. Press “CH +” repeatedly, to go to parameter 24 - indicated as “P 24” on the display.

3. Press either the “DHW +” or “DHW –” button until the desired setpoint is reached.

4. Press the “Conrm” button to conrm the change.

5. Press the “Conrm” and “DHW Mode” buttons for 3 seconds.

6. Observe that “Para” is ashing on the display.

3.8.5

FINDING THE MASTER BOILER

The master boiler displays the water temperature if there is no error message. The slave boilers will

display “SLA X” where X is the address of the slave.

If there is an error message then the master boiler will display “XYZZ”, where:
X is the address of the boiler, where the error is located
Y can be the letter A or E depending on whether it is a lock out error (A), or only a limiting condition

(E)- ZZ is the error code. Refer to Section 4.13 for details of error codes.

A slave boiler will only display “YZZ”, where Y and Z are as described above.

3.8.6

BOILER OPERATION

The boiler will start ring by linking the DHW demand terminals, normally performed by a switch or a

thermostat. For the duration of the heat demand the boiler(s) will modulate to the setpoint

temperature. The boiler stops heating when it reaches the setpoint plus 5°C and starts up again

when the temperature drops below the setpoint.

Pumps will overrun a certain time, as specied by “P 07” in Installer+ mode.

Where there is more than one boiler module in the system, the active sensor will be the cascade

sensor, which is normally placed after the header on the common ow pipe.

In the case of one installed boiler, the temperature sensor can also be the cascade sensor. If there

is no cascade sensor installed, then the boiler will modulate according to the water ow temperature

sensor -this is an integral part of the boiler, factory tted as standard.

3.8.4

CHANGING THE TEMPERATURE SETPOINT FOR CH

1. Press either the “CH +” or “CH –” button until the desired setpoint is reached.

2. Press the “Conrm” button to conrm the change.

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1. Turn off electrical power.

2. Close all manual gas valves.

3.9

SHUTDOWN PROCEDURES

3.9.1

NORMAL SHUT OFF PROCEDURES

3.9.2

EMERGENCY SHUT OFF PROCEDURES

The main gas cock should be closed immediately. If overheating occurs or the gas supply fails to

shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas
supply at a location external to the boiler.

3.9.3

SHUTTING THE BOILER DOWN FOR AN EXTENDED PERIOD OF TIME

Press ‘CH MODE’ and ‘DHW MODE’ on the display together and keep pressed for at least 3 seconds.

The boiler now enters suspend mode. Only frost protection is active. Refer to Section 2.6 for details

of Frost Protection operation.

3.9.4

STARTING THE BOILER AFTER PROLONGED SHUTDOWN

Perform initial start up procedures as described in this manual.

3.8.7

AUTO DETECTION

If error FE97 occurs, it is most likely a mismatch in the cascade system due to a change in the
number of boilers or boiler settings. In this case perform an Auto Detection by holding “CH –” button
on the display of the master boiler for 3 seconds.

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The user interface is an LCD display with 7 buttons. User interface functions are grouped to UI

operating modes described in Section 3.15.

FIG. 10 LCD GLASS LAYOUT

3.10

DISPLAY OPERATION

3.11

SYMBOLS ON THE LCD

The FHE-250 is equipped with an LCD display capable of showing four full 7-segment digits and a

set of additional icons showing information about the current state and operating mode of the device.

Four 7-segment digits and alternatively partially implemented fth digit are used for displaying

numeric values and some letter indication. Total number of LCD segments is 60. Their description

with details and placement are described on Fig. 10 and Fig. 11.

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Typical usage of segments:

ot OpenTherm master detected

i1 + i2 Installer mode indication

rf1 + rf2 Not used

reset1 Indication of possibility to reset lockout error

reset2 Not used

spn Installer+ mode indication

stb Suspend mode indication

otc Outside temperature sensor is connected

ch Indication of CH service or CH setpoint adjustment when blinking

sun Summer indication

pmp Pump activity indication

m Flame presence indication

doff DHW-off (eco) indication

dhw Indication of DHW service or DHW setpoint adjustment when blinking

dgr Degree symbol

bar Bar (pressure) symbol

col No specic usage

P1 Detected slave DSP device in chain below

P2 Various functions -mainly answer button indicator

P3 On, when information is related to MAXSYS1

P4 Detected master DSP device in chain above

P5 Not used yet

P6 On, when information is related to MAXSYS0

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The Display is equipped with 7 push-buttons placed round the LCD display as follows:

A B C

E

F

G

D

FIG. 11 PUSH-BUTTON LAYOUT

The Display is equipped with a blue LED backlight. The backlight operation is as follows:

The Backlight:

• is activated for 10 seconds when Standby mode is entered.

• is turned off immediately, when Suspend mode is entered.

• is on during the Auto Detection procedure.

• is activated for 30 seconds after any button activity.

• blinks when an error is indicated.

3.12

PUSH-BUTTONS

3.13

BACKLIGHT

3.14

USER INTERFACE OPERATING MODES

The display supports switching among various user interface operating modes. The very rst

mode invoked after startup of the system is Initial mode.

3.14.1

INITIAL MODE

LCD- rst screen for 2 seconds

seg1 to seg4 : Displayed text “CASC”

LCD- second screen for next 2 seconds:
seg1 to seg4 : Displayed DSP software version number

Buttons- no activity

Note: After 2 seconds of showing the second screen, the boiler is switched to Standby mode.

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The boilers are in standby mode unless they run into an error condition. In standby mode the

boiler displays the temperature of the supply water. Cascade temperature is displayed if the

cascade temperature sensor is installed (normally placed after the header). Otherwise the

supply temperature sensor is displayed on the LCD.

In error condition the boiler will show the error code starting with the address of the boiler that

produced the error code (F is related to the display), then the type of the error (A is lock-out

error, E is a limiting condition) and a two digit number which designates the type of the error.

Refer to Section 4.13 for details of error codes.

LCD -without error condition:

seg1 to seg3 Displayed CH supply temperature, otherwise blinking “--” is displayed
dgr + seg5 Symbol °C or °F if CH supply temperature value is valid
P1 Indication of presence of slave DSP, off on terminal DSP
pmp Indication of pump running

m Indication of ame present

sun Displayed when CH mode is inhibited (SUMMER)
doff Displayed when DHW mode is inhibited (DHW-OFF / ECO)
ch Indication of CH mode service
dhw Indication of DHW mode service
ot OpenTherm master detected
otc Outside temperature sensor is connected

LCD -during error condition:

seg1 Displayed source of error (master only).
seg2 Displayed “A” for lockout error, “E” for non-locking error.
seg3 to seg4 Error code displayed
P1 Indication of presence of slave DSP, off on terminal DSP
pmp Indication of pump running

m Indication of ame present

sun Displayed when CH mode is inhibited (SUMMER)
doff Displayed when DHW mode is inhibited (DHW-OFF / ECO)
ch Indication of CH mode service
dhw Indication of DHW mode service
ot OpenTherm master detected
otc Outside temperature sensor is connected
P2 Blinking when lockout error is displayed
reset1 Blinking when lockout error is displayed
P6 Blinking when error is related to MAXSYS0, or local device at position of MAXSYS0
P3 Blinking when error is related to MAXSYS1, or local device at position of MAXSYS1

3.14.2

STANDBY MODE ON MASTER DSP

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Button Press: Function:

Briey D Enter CH setpoint adjust mode
Briey E Enter CH setpoint adjust mode
Briey F Enter DHW setpoint adjust mode
Briey G Enter DHW setpoint adjust mode
Briey A Toggle SUMMER mode
Briey B Reset lockout error (if lockout error is present)
Briey C Toggle DHW-OFF mode

A+C for 3 sec. Enter Suspend mode
A+B for 3 sec. Enter Cascade test mode

B+C for 3 sec. Enter Installer+ mode

A for 3 sec. Enter Local test mode

B for 3 sec. Enter Local installer mode
C for 3 sec. Enter History mode
D for 3 sec. Start of Auto Detection procedure
E for 3 sec. Invoke parameter load on all DSPs

Note: The Master DSP is capable of displaying the source of error. Burners are indicated by their address “0” to

“E”(0,1,2,3,4,5,6,7,8,9,A,B,C,D,E). Source of error coming from DSP is identied by address “F”.

3.14.3

STANDBY MODE ON SLAVE DSP

In normal operation the slave boilers will be in standby mode, where “SLA” plus a one digit
number is displayed, which is the address of the boiler.
In error condition, the display will show the type of the error (A is lock-out error, E is a limiting
condition) and a two digit number which designates the type of error. Refer to Section 4.13 for
details of error codes

LCD:

seg1 to seg3 Displayed text “SLA” as slave device indication

seg4 Order of device in chain

P4 Indication of presence of master DSP in chain -always on

P1 Indication of presence of slave DSP, off on terminal DSP

pmp Indication of pump on local boiler

m Indication of ame on local boiler

Button Press: Function:

D for 3 sec. Start of Auto Detection procedure

B for 3 sec. Enter Local installer mode

A for 3 sec. Enter Local test mode

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LCD:

seg1 to seg3 Displayed setpoint value, if not available “--” is displayed, blinking when

adjusted

dgr + seg5 Symbol °C or °F if temperature value is valid

ch Always blinks

P2 Blinks when parameter is modied and can be saved.

Button Press: Function:

D (autorepeat) Decrement setpoint value

E (autorepeat) Increment setpoint value

Briey B Write setpoint value if modied and exit

Note: After 10 seconds of keyboard inactivity, mode exits without updating the setpoint value.

3.14.5

CH SETPOINT ADJUST MODE

3.14.4

SUSPEND MODE

LCD:

stb Always on

P2 Always blinking

Button Press: Function:

D for 3 secs. Start of Auto Detection procedure

Briey B Exit from Suspend mode to Standby mode

Note: In the Suspend mode, both BH and DHW service is inhibited with exception of frost protection.

A

B

C

E

D

G

F

A + C for 3 sec.

D briey.

A

B

C

E

D

G

F

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3.14.6

AUTO DETECTION MODE

LCD:

seg1 to seg4 Displayed blinking text “Auto” during local MAXSYS detection

Displayed blinking text “PArA” during parameter load from MAXSYS0

Displayed text “bu” when asking for burner count conrmation & burner count

Displayed blinking text “Auto” during cascade DSP detection

col Blinking when asking for burner count conrmation

P2 Blinking when asking for burner count conrmation

Button Press: Function:

Briey B Conrmation of burner count, when asked

Note: Auto Detection invalidates cascade structure information. If burner count is not conrmed by installer,
normal operation is blocked by F97 error. To allow the system to function correctly, all devices must be present,
cascade must be started again and burner count must be conrmed by installer.

3.14.7

CASCADE TEST MODE

LCD:

seg1 Displayed “C”

seg2 to seg4 Percentage of power demand of the cascade

Button Press: Function:

A+B for 3 sec. Exit cascade test mode

D (autorepeat) Decrement power demand

E (autorepeat) Increment power demand

Briey F Set power demand to 0% (absolute minimum).

Briey G Set power demand to 100% (absolute maximum).

D for 3 sec.

A

B

C

E

D

G

F

A

B

C

E

D

G

F

A + B for 3 sec.

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LCD:

seg1 Displayed “t”

seg2 to seg4 Percentage of power demand of the cascade

P6 Blinking when testing local device at position of MAXSYS0

P3 Blinking when testing local device at position of MAXSYS1

Button Press: Function:

A for 3 sec. Exit local test mode

D (autorepeat) Decrement power demand

E (autorepeat) Increment power demand

Briey F Set power demand to 0% (absolute minimum).

Briey G

Set power demand to 100% (absolute maximum).

Note: MAXSYS0 refers to a unit with LCD display and MAXSYS1 refers to a unit without display.

3.14.8

LOCAL TEST MODE

A for 3 sec.

A

B

C

E

D

G

F

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3.14.9

LOCAL INSTALLER MODE

LCD -when showing the parameter index:

seg1 Displayed “P”

seg2 to seg3 Index number (starting from 1)

i1 Installer mode indication

P6 Blinking when MAXSYS0 as the source is selected

P3 Blinking when MAXSYS1 as the source is selected

LCD -when showing the parameter value:

seg1 to seg3 Numeric value (refreshed every 3 sec.)

i1 Installer mode indication

P6 Blinking when MAXSYS0 as the source is selected

P3 Blinking when MAXSYS1 as the source is selected

Button Press: Function:

B for 3 sec. Exit local installer mode

Briey A Exchange burners (in case of two burners per display)

D Decrement index number

E Increment index number

P01 Flame current [uA]

P02 CH supply temperature [ºC -or-ºF]

P03 CH return temperature [ºC -or-ºF]

P04 DHW temperature [ºC -or-ºF] (only on MAXSYS0, if used)

P05 Water pressure [bar/10 -or-psi] (local MAXSYS0, where sensor is connected)

P06 Output level [rel. %] Actual relative output level of the burner

P07 Requested fan speed [50*rpm] Speed requested by control algorithm

P08 Actual fan speed [50*rpm] Fan speed

P09 Exhaust temperature [ºC]

P10 Cascade temperature [ºC -or-ºF], if cascade sensor is connected

P11 OTC temperature [ºC -or-ºF] temperature from external sensor

P12 Cascade mod. level [rel. %] relative modulation level of cascade

P13 CH control setpoint [ºC -or-ºF]

P14 DHW control setpoint [ºC -or-ºF]

P15 Total burners Total count of installed burners

P16 Total burners on Count of burners running

P17 Total displays Total count of boiler modules

Note: MAXSYS0 refers to a unit with LCD display and MAXSYS1 refers to a unit without display.

A

B

C

E

D

G

F

B for 3 sec.

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3.14.10

HISTORY MODE

LCD -when selecting the burner:

seg1 to seg2 Displayed “bu”

seg4 Burner number (from 0 to E)

LCD -when selecting the history index:

seg1 to seg2 Displayed “Hi”

seg3 to seg4 Index number (starting from 0)

LCD -when showing the error code:

seg2 to seg3 Numeric value (refreshed every 3 sec.)

Button Press: Function:

C for 3 sec. Exit history mode

Briey B Conrm selection and shift to the next page (burner -> index -> code)

D Decrement index number, skip to index selection screen

E Increment index number, skip to index selection screen

F Decrement burner number, skip to burner selection screen

G Increment burner number, skip to burner selection screen

Note: When the mode is invoked, indicates burner selection. User interface is switched to Index selection after 3
seconds or on demand. Index starts from number 0. After 1 second index is replaced by related error code.

A

B

C

E

D

G

F

C for 3 sec.

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LCD -when selecting the parameter index:

seg1 Displayed “P”

seg2 to seg3 Index number (starting from 1)

i1 + i2 + spn Installer+ mode indication

LCD -when showing value:

seg1 to seg3 Displayed value, if not available a string “--” is displayed, blinking when

adjusted

P2 Blinks when parameter is modied and can be saved

i1 + i2 + spn Installer+ mode indication

Button Press: Function:

B+C for 3 sec. Exit Installer+ mode

Briey B Write value if changed, switch between index and value screens

D (autorepeat) Decrement index number, skip to index selection screen

E (autorepeat) Increment index number, skip to index selection screen

F (autorepeat) Decrement parameter value

G (autorepeat) Increment parameter value

Note: After each exit of Installer+ mode, the parameter load request is sent to all DSPs in the chain. This takes
approx 15 seconds to complete.

3.14.11

INSTALLER+ MODE

A

B

C

E

D

G

F

B + C for 3 sec.

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P01 CH setpoint [°C -or -°F]

P02 CH setpoint max. [°C -or -°F]

P03 CH hysteresis [°C -or -°F] (differential unit)

P04 CH anticycle [min]

P05 CH minimum time [min]

P06 CH slope [°C/min -or -°F/min] (differential unit)

P07 CH pump overrun [min]

P08 CH max. capacity [rel. %] limitation of maximum of the capacity

P09 CH min. capacity [rel. %] limitation of minimum of the capacity

P10 CH Kp CH PI control coefcient

P11 CH Ki CH PI control coefcient

P12 CH minimal mod. level [abs. %] absolute level related to minimum of modulation

P13 CH max burner power [kW -or -kBTU/h] power per burner

P14 OTC curve Slope number of the OTC curve

P15 OTC offset [°C -or -°F] Offset of the OTC curve

P16 DHW setpoint [°C -or -°F]

P17 DHW setpoint max. [°C -or -°F]

P18 DHW hysteresis [°C -or -°F] (differential unit)

P19 DHW pump overrun [sec] (not applied to cascade pump)

P20 DHW max. capacity [rel. %] limitation of maximum of the burner capacity

P21 DHW min. capacity [rel. %] limitation of minimum of the burner capacity

P22 DHW Kp DHW PI control coefcient

P23 DHW Ki DHW PI control coefcient

P24 DHW storage setpoint [°C -or -°F]

P25 DHW storage add.off [°C -or -°F] (differential unit)

P26 DHW overtemp. timer [sec]

P27 FAN max. speed [50*rpm]

P28 FAN min. speed [50*rpm]

P29 FAN Kp -up FAN PI control coefcient

P30 FAN Ki -up FAN PI control coefcient

P31 FAN Kp -down FAN PI control coefcient

P32 FAN Ki -down FAN PI control coefcient

P33 Ignition level [rel. %] 0..100% between min and max of burner

P34 Market zone 0..127 = metric units, 128..256 = imperial units

P35 Pump PWM -min. [%] minimum PWM duty of system pump

P36 Pump PWM -max. [%] maximum PWM duty of system pump

P37 DHW split burners number of burners for DHW service in case of splitted system

P38 Cascade frost on level [°C -or -°F] level to trigger frost protection on cascade sensor on

P39 Cascade frost off level [°C -or -°F] level to trigger frost protection on cascade sensor off

P40 Cascade switch delay [sec] time to

P41 DSP PI loop period [sec] period of PI calculation/integration step in DSP

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It is the law that any service work must be carried out by a Gas Safe Registered Engineer in the UK.

In IE service work must be carried out by a competent person.

SECTION 4 - MAINTENANCE

!

WARNING

Always turn off the gas supply at the gas service cock, and switch off and disconnect the electricity

supply to the appliance and any external controls before servicing or replacing components.

Maintenance on Gas appliances should only be carried out by competent, trained personnel who are

‘Gas Safe’ registered in the UK, and who have the necessary equipment to check combustion. If any

fault is found during these operations contact your Fulton representative.

Make the following checks for correct operation.

1. The correct operation of ANY secondary system controls should be proved. Operate each

control separately and check that the main burner or circulating pump, as the case may be,
responds.

2. Water circulation system;

a) With the system HOT examine all water connections for soundness.

b) With the system still HOT, turn off the gas, water and electricity supplies to the boiler and

drain down to complete the ushing process.

c) Rell and vent the system, clear all air locks and again check for water soundness.

d) Balance the system.

3. Check the condensate drain for leaks and check it is discharging correctly.

4. Finally set the controls to the User’s requirements.

Note. If optional kits are tted then refer to the instructions supplied with the kits.

4.1

GENERAL

4.2

SAFETY

IMPORTANT NOTE: After completing the servicing or replacement of components always:

1. Test for gas soundness.

2. Test the burner manifold anges for soundness. This can be done with leak detection spray whilst

operating the boiler. The gas valve and controls must be shielded from the spray.

3. Check the water system is correctly lled and free of air. Air in the boiler could cause damage to
the heat exchanger. For this reason a non-isolatable automatic air vent is tted as standard on

all FHE boilers.

4. Check the module cover panels are correctly tted.

5. With the system hot examine all water connections for soundness.

CONTINUED...

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250 kW

Flue Gas CO

2

@ Max Rate % 9.0 ± 0.3

G20/LNG @ Min. Rate % 9.0 ± 0.3

*Same values apply to
models 500, 750 and 1000.

6. Check the gas rate and measure the combustion CO/CO2 content. The CO/CO2 ratio of the ue
gas on each module should not be greater than 0.004. The CO2 values should be correct to the

following gures:

Carry out functional checks as appropriate.

4.3

PARTIAL ISOLATION OF BOILERS IN CASCADE SYSTEMS

It is possible to continue normal operation of the boilers without any changes to the wiring,
in the event that one of the boilers in the chain is either not in working condition, or is under
maintenance. Perform one of the following procedures depending on which boiler is not in
service.

!

WARNING

Always isolate all of the boilers from the main electrical supply before

executing these procedures.

Note:

a) All changes to terminals as listed below are in accordance with the terminal number tables in Section 2.19.2

of this manual.

b) The letter “N” below indicates the total number of installed boilers.

1. Remove the lower front panel of any boilers requiring changes, to access the necessary
electrical terminals.

2. After any changes on boiler setup always perform an Auto Detection procedure as detailed in

Section 3.8.7 of this manual.

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4

1. ISOLATING THE MASTER BOILER *

Master boiler: Disconnect all terminal plugs

Slave 1 boiler: Connect all of the terminal plugs

All remaining Slave boilers: No Change

2. ISOLATING A SLAVE BOILER IN THE CHAIN (EXCEPT THE LAST ONE) *

Master boiler: No Change

Slave boiler to isolate: Disconnect Terminal plugs 1-13 and insert jumpers between:

• Terminal 14-15

• Terminal 16-17

• Terminal 18-19

All remaining Slave boilers: No Change

3. ISOLATING THE LAST SLAVE BOILER *

Master boiler: No Change

Slave boilers up to Slave N-2 boiler: No Change

Slave N-1 boiler: Disconnect Terminal 20 and connect Terminal 19

Last Slave boiler in chain: Disconnect all terminal plugs

4. ISOLATING THE MASTER BOILER AND A SLAVE BOILER *

Master boiler: Disconnect all terminal plugs

Slave boiler out of order: Disconnect Terminal plugs 1-13 and insert jumpers between:

• Terminal 14-15

• Terminal 16-17

• Terminal 18-19

First working boiler in chain: Connect all of the terminal plugs

All remaining Slave boilers apart from last: No Change

Last working Slave boiler: To be set up as instructed for the last Slave in

Section 2.19.2

Note:

The isolated boiler becomes invisible to the controller.

The rst working boiler becomes the Master Boiler.

a) Boilers out of order after the new master need to have 3 jumpers inserted between:

• Terminal 14-15

• Terminal 16-17

• Terminal 18-19

b) Additionally Terminals 1-13 need to be disconnected.

c) Ensure Terminal 20 is connected and Terminal 19 is disconnected on the last working boiler.

* For details of terminal disconnection and jumper insertion, refer to Figs 7, 8 & 9 on page 24 of this manual

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To ensure the continued safe and efcient operation of the boiler, it is recommended that it is checked

at regular intervals and serviced as necessary. The frequency of servicing will depend upon the
installation condition and usage but should be carried out at least annually.

Fulton Ltd does not accept any liability resulting from the use of unauthorised parts or the repair and
servicing of appliances not carried out in accordance with the Company’s recommendations and

specications.

Note: Some build-up within the heat exchanger assembly is quite usual with this type of condensing boiler.

Thorough removal and cleaning is recommended annually, the heat exchanger must be inspected and cleaned

after a maximum of 2 years operation.

1. Light the boiler and carry out function checks, noting any operational faults.

2. Run the boiler for 5 minutes and then check the gas consumption rate.

3. For correct boiler operation, the CO/CO2 ratio of the ue gas on each module should not be
greater than 0.004 and the CO2 values should be correct to the gures in Section 4.2.

4. Remove and inspect the fan/venturi assembly.

5. Remove the burner assembly and inspect the electrodes and sightglass.

6. Remove and clean the burner.

7. Inspect the heat exchanger through the burner opening. If there are signs of oxide build up,
clean the exposed heat exchanger surface with a suitable brush.

8. Clean the condensate trap(s).

9. Check that the ue terminal and air inlet are unobstructed and that the uing and ducting are

correctly sealed.

REPEAT PROCEDURE FOR SLAVE AND MASTER MODULES.

10. After servicing refer to Section 4.2 for nal safety checks.

CAUTION

Use caution when using any cleaning solutions.

Refer to local regulations for proper cleaning solution disposal.

!

CAUTION

Do not allow oil leaks, dust, or dirt to accumulate around the boiler.

!

4.4

SERVICING SCHEDULE

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Daily maintenance and inspection must include the following:

1. Observe general conditions and operating temperature.

2. Make sure that the ow of combustion and ventilating air to the boiler is not obstructed.

3. Assure that boiler area is free and clear of any combustible materials, including ammable

vapours and liquids.

CAUTION

Hazard analysis should be performed by the end user to ensure the safety of employees/personnel.

!

4.4.1

DAILY MAINTENANCE AND INSPECTION

4.4.2

WEEKLY MAINTENANCE AND INSPECTION IN ADDITION

Weekly maintenance and inspection must include the following:

4. Observe the conditions of the main ame. A normal high re ame shows an orange screen with

a blue halo. In Low re the burner should display a reddish orange glow.

5. Correct air adjustment is essential for the efcient operation of this boiler. If an adjustment to the

combustion is necessary, the ue gas composition should be checked with a carbon dioxide

(CO2) or oxygen (O2) analyser to set conditions.

4.4.3

MONTHLY MAINTENANCE AND INSPECTION IN ADDITION

Monthly maintenance and inspection must include the following:

6. Remove and clean out the condensate trap pipework arrangement.

7. Test high-limit control by reducing setting below the operating temperature. Burner should shut

off. Return high limit to previous setting.

8. Test operating temperature control by reducing temperature setting as necessary to check
burner operation.

9. Check ue gas temperature at outlet. If there is a temperature increase over previous readings,
the probable cause is soot or water-scale build-up on the tubes. Consult Fulton immediately if
there is a concern.

10. Test low gas pressure switch utilising the procedure in Section 3.6.

11. If an air inlet lter is included with the boiler, inspect and clean lter of any dust or lint.

See Section 4.5 Procedure for Cleaning the Air Inlet Filter.

12. Verify the water loop style traps in the exhaust venting system are ooded.

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Annual maintenance and inspection must be performed prior to each heating season, and includes

the following tasks which must be done by a factory trained technician.

Observe the general operation of the unit to verify the following:

13. Stack temperature readings are in line with factory test re and regular maintenance reports.

14. Boiler is lighting reliably and quietly.

15. There are no unusual sounds coming from the burner or blower assembly.

16. It is considered good practice to remove and inspect the burner and ignition assembly on an
annual basis. Follow Section 4.7 Procedure for Removing/Cleaning Burner in this manual if
there is evidence of foreign matter built up on the burner or ignition assembly.

17. The heat exchanger must be inspected and cleaned, as needed. Follow Section 4.9 Procedure

for Cleaning the Heat Exchanger in this manual.

CAUTION

Any damage to the burner or any other aspect of the boiler because of an air lter that was not cleaned

and maintained regularly will void the warranty.

!

4.4.4

ANNUAL MAINTENANCE AND INSPECTION IN ADDITION

4.5

PROCEDURE FOR CLEANING THE AIR INLET FILTER

The air lter is an optional part and does not come with every boiler.

Proceed as follows:

1. Remove the lter. The lter sits between the air inlet connection to the venturi and an adapter
plate, bolted to each corner of the venturi ange, accessible from the front of the boiler.

2. Remove all debris and dirt from the lter using a vacuum cleaner.

3. Return the lter to its original position in the slot.

Note: Where an internal ductwork arrangement is also included in the boiler for room sealed applications, the lter

will not be accessible for cleaning and it must be removed along with the foam gasket tape between the venturi
and adapter plate and both the tape and lter should be replaced.

4.6

EXAMINE THE FLUE SYSTEM

1. Check all joints and pipe connections for tightness.

2. Check vent for corrosion or deterioration. If any venting needs replacing, do so immediately.

3. Perform any recommended maintenance as required by the vent material manufacturer.

4. Check to ensure loop traps are ooded.

4.7

INSPECT HEATING SYSTEM FOR OTHER PROBLEMS

1. Perform combustion analysis and adjust if necessary.

2. Leak test gas valves. Leak Test must be performed only by qualied personnel, who have been

trained in this procedure by Fulton.

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Note: Ensure the gas supply to the boiler and the mains electricity supply have been isolated prior to
commencing this work.

Perform the following to remove/clean the burner:

1. Remove the top and both front panels from the boiler frame, carefully disconnecting the 3 block
connectors on the controller on the top front panel:

• black 12 pin connector block, with wiring labelled “DSP X01”

• black 10 pin connector block, with wiring labelled “DISP X04”

• white 6 pin connector block, with wiring labelled “DSP X05”

Store all panels in a safe location.

2. Disconnect both block connectors from the pre-mix blower:

• white 3 pin connector block, with wiring labelled “FAN X1”

• white 4-pin connector block, with wiring labelled “FAN X2”

3. Disconnect the 2 grey angled block connectors from the gas valve and gas pressure switch:

• wiring labelled “GAS PL1” from the gas valve

• wiring labelled “GAS PS1” from the gas pressure switch

Note: Each of these connectors in point 3 is secured in place with a screw headed M4 bolt.

4. Ensure the entire gas valve/venturi/blower assembly is supported ready for removal.

5. Disconnect the four allen bolts from the bottom of the gas valve. Inspect the o-ring located

between these two anges for signs of deterioration, replace if required.

6. Disconnect the 4 M8 bolts securing the gas valve/venturi/blower assembly to the apper, lift the

entire assembly out of the unit and put in a safe position where no dust or other contaminants

can get into the assembly. Inspect the square rubber gasket between the blower and the apper

for signs of deterioration, replace if necessary.

Note: Adequate preparation and care should be taken when removing this assembly, as it is heavy.

7. Disconnect the cables from the ignition transformer, the ionisation probe and the ignition

electrode:

• brown cable with an angle rajah connector, labelled “ION” from the ionisation probe on the

bottom front of the heat exchanger

• orange cable with an angle rajah connector between the ignition transformer (top left corner)

and the ignition electrode on the right hand side of the front of the heat exchanger

• green & yellow cable with a spade connector, labelled “earth” from the connector next to the

ignition electrode

• white 6-pin connector block, with wiring labelled “FLAP X3” from the apper block connector

8. Undo the four nuts holding the apper-mounting plate to the heat exchanger.

4.8

PROCEDURE FOR REMOVING/CLEANING THE BURNER

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9. Remove the burner, being careful not to scrape it on the heat exchanger. Inspect the gasket for
signs of deterioration, replace if necessary.

10. Inspect the burner and wipe off (do not scrub or use a wire brush) any soot or foreign material that
may have accumulated. If available, use compressed air to clear the burner. Wipe out the inside
of the burner with a clean cloth.

11. Check the gap between the electrode and the ground rod.
Gap should be 1/8 inch (3 mm) +/- 1/16.

12. Check the horizontal gap between the point of ignition and the exterior of the mesh burner. The
required gap is 5/16-3/8 inch (8-10 mm).

13. To inspect the gasket between the apper mounting plate and mesh burner undo the 4 bolts.

14. Check for cracking of the electrode insulator. Do not over tighten the electrode.

15. Use a soft, clean cloth to remove accumulated contaminants from the sight glass.

16. 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.

17. Reverse removal steps for reinstallation of the burner assembly.

18. Reinstall front and top panels.

19. Test re the boiler and use a combustion analyser to ensure that the fuel/air ratio is set correctly

throughout the range.

Note: This work should normally be carried out in conjunction with the annual removal and cleaning of the burner,

as detailed in Section 4.8 above. Follow steps 1 to 9 above in order to gain access to the heat exchanger.

4.9

PROCEDURE FOR CLEANING THE HEAT EXCHANGER

Inspect the heat exchanger, and clean if necessary using the following procedure:

1. Inspect the tubes for any signs of damage.

2. Vacuum out any deposits inside the combustion chamber area if necessary.

3. 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.

4. Vacuum again to remove any debris from brushing the heat exchanger.

5. Wipe down with a clean wet cloth.

6. Inspect the refractory at the back of the combustion chamber.

7. If there are any signs of damage, the insulation disc must be replaced.

8. If the ignition assembly or ame rod were removed for any reason, inspect these gaskets for

signs of damage, and replace if damaged.

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If the boiler installation contains more than 1 module, each boiler module will be tted with individual

gas valves, all gas valves must be adjusted independently.

Note: The procedure for each boiler module will be the same, the ue gas analyser must be connected to each
boiler ue prior to its’ connection into any common ue header.

Maximum rate adjustment (Throttle)

1. Switch the boiler on and operate for 5 minutes.

2. Set the module to maximum output.

3. Connect a suitable ue analyser to the ue sampling point of the boiler.

4. Using the maximum rate adjustment screw, adjust the master module gas valve, if necessary,
until the CO2 measures 9.5% ± 2.5 (nb. clockwise reduces CO2).

Minimum rate adjustment (Offset)

5. Set the module to minimum output.

6. Connect a suitable ue analyser to the ue sampling point of the boiler.

7. Remove the protective cap and then using the offset adjustment screw, adjust the valve on the
boiler until the CO2 value measures 9.5% ± 2.5 (nb. anti-clockwise reduces CO2 level).

Note: The offset adjustment is more sensitive than the throttle adjustment.

IMPORTANT NOTE: The CO measurement when the CO2 is set, should not exceed 50 ppm. Under no

circumstances should the CO/CO2 ratio exceed 0.004.

Adjust in steps of no more than 1/8 turn and wait 1 minute after each adjustment to allow setting to

stabilise.

8. Re-check the CO2 level at the boiler maximum output, repeating steps 2 to 7 if necessary.

9. Seal adjustment screw cap with tamper proof paint.

10. If the required CO2 level cannot be obtained with a CO/CO2 ratio below 0.004 then contact
Fulton.

4.10

GAS VALVE ADJUSTMENT

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1. Follow Section 4.2 Safety in this manual and all relevant safety checks.

2. Fire the boiler and perform combustion check. Analyse combustion throughout the range and
verify proper operation of safety devices.

3. Make any necessary adjustments.

4.11

AFTER ALL REPAIRS AND MAINTENANCE

4.12

HANDING OVER

Routine Operation

Draw the attention of the boiler owner or his representative to this manual. Give a practical
demonstration of the lighting and shutting down of the boiler.
Describe the function of the boiler and system controls and show how they are adjusted and used.
Hand these Installation and Servicing Instructions/User’s Instructions and Log book to the customer
and request him to keep them in a safe place for ready reference. For IE, it is necessary to complete
a “Declaration of Conformity” to indicate compliance to the appropriate standard.

IMPORTANT NOTE: Point out to the owner that the boiler must have regular maintenance and cleaning, at least
annually, in order to ensure reliable and efcient operation. Regular attention will also prolong the life of the boiler
and should preferably be performed at the end of the heating season.

After servicing, complete the service section of the log book and return to the owner or their representative.
Recommend that a contract for this work should be made with the regional gas authority or a Gas Safe Registered
Engineer. In IE servicing work must be carried out by a competent person.

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Error codes can be divided into 2 groups:

1. Lock-out error codes

2. Blocking error codes

4.13

ERROR CODES AND TROUBLESHOOTING

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1. LOCK OUT ERROR CODES

Lock out error codes require a manual reset action after the source of the problem has been identied and eliminated. The meaning of the error numbers

are as follows:

ERROR

CODE

MEANING POSSIBLE CAUSE SOLUTION

A1

Lock out signal after no ame and all ignition trials are

expired

Description:

This error condition stops the boiler from operating and

manual/remote reset is required. Local resets are not

limited. However remote resets (communication or

Open Therm) are limited to 5 per hour.

a) Manually operated valves on the

gas train have been closed.

b) There is a blockage in the gas

line.

c) Modulating gas valve within the

boiler is not operating correctly.

d) Modulating gas valve within the

boiler has failed.

a) Check and open the manually operated valves

including the T-handle valve in the boiler shell.

b) Check the operation of any other equipment,

connected upstream of the boiler, on the gas line.

c) Check the tube between the gas valve and the

Venturi and ensure that both ends are properly

connected.

d) Replace the modulating gas valve.

A2 False Flame Signal

A ame signal is seen without the

gas valve being open.

Clean isolation probe. Reset lockout.

A3

Overheat Protection

Description:

This error code can be generated by one of two methods of

overheat protection built into the boilers. A High Limit error

can be generated even after a CH supply or return sensor

short circuit condition occurs.

There is a signal coming from the

CH ow or return temperature

sensors in excess of 105°C, or the

heat exchanger body is higher than

95°C, so the circuit is open through

the high limit stat (this is normally

closed).

a) Clean CH ow and return temperature sensors.

b) Check wiring between the controller and the limit

stat and make sure that the wires connected are

not loose. If all the wiring is ne then replace the

high limit stat.

c) If the problem still persists, then replace ow and

return temperature sensors

A4

APS (Air Pressure Switch) Error

Description:

The APS is congured and does not close or does not open

within set time limits. Error 4 is generated.

APS ap valve has stuck open, or

closed.

Remove the apper house between the fan and the

heat exchanger and clean the housing inside. If this

does not solve the problem, then replace the APS

apper.

A5

Fan Speed Feedback Error

Description:

The control requires a certain fan speed, but does not

detect the correct signal.

The fan motor is not working

correctly.

Replace the fan unit on the burner.

A6

APS (Air Pressure Switch) Error

Description:

If the APS is congured and it drops during burner

operation and the number of maximum re-trials has been

reached, Error 6 is generated.

A foreign body blocking the air

supply.

Check that the airway to the burner is clear from

obstructions.

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ERROR

CODE

MEANING POSSIBLE CAUSE SOLUTION

A9

Valve Circuit Error

Description:

During normal operation of the MaxSys controller, the valve

circuit is regularly checked. If the check fails, Error 9 will be

set.

There is a problem with the gas

valve.

Replace the modulating gas valve

A11

Temperature sensor self test on the boiler heat

exchanger has failed

a) Water ow in the system has

reversed.

b) Temperature sensors are scaled

up.

a) If it happens at rst start up then check that the

ow and return pipes have been installed

correctly. Check the direction of the water pump.

b) Clean or replace sensors

A13 Remote Reset Inhibit

The boiler has been attempted to

reset remotely more than 5 times in

15 minutes.

Inspection by a competent person is recommended.

Reset can be achieved by switching the isolation

switch off and on.

A15

Drift Test Error

Description:

When the boiler is unable to start up due to a consistent

error described under error code E81, then the boiler is

locked out with error code A15.

See error code E81 See error code E81

A16

Stuck at Test Error on CH Supply Sensor

Description:

When temperature rise cannot be detected on the supply

sensor after successful ignition, error code A16 is set.

a) The sensor has been removed

from the pocket.

b) The sensor is faulty.

a) Insert the sensor back into place

b) Replace the sensor

A17

Stuck at Test Error on CH Supply Sensor

Description:

When temperature rise cannot be detected on the supply

sensor after successful ignition, error code A17 is set.

a) The sensor has been removed

from the pocket.

b) The sensor is faulty.

a) Insert the sensor back into place

b) Replace the sensor

A18

Cracked Sensor Test Error

Description:

When a large crack in the CH Supply or CH Return Sensor

is detected, error code A18 is set.

The Supply or Return Sensor is

cracked.

Replace the sensor

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ERROR

CODE

MEANING POSSIBLE CAUSE SOLUTION

A30

CH supply sensor out of normal operating range

(short circuit)

The CH supply sensor is damaged. Replace the CH supply sensor.

A80

Supply-Return Reversed Error

Description:

CH Supply and Return temperature sensors are

monitored after ignition. If the return water temperature

is higher, then the boiler will be locked out.

The water ow is reversed in the

system

Check the circulation pumps and resolve the

problem

A31

CH supply sensor out of normal operating range

(open circuit)

The CH supply sensor is damaged. Replace the CH supply sensor.

A43

CH return sensor out of normal operating range

(short circuit) - resolving type

Description:

If NTC sensor goes outside the range, a warning will be

generated.

When the sensor is back to the normal operating range, the

warning is gone.

The warning will switch off the system. Heat demands will

be disabled.

Resolving the situation can be achieved only if the sensor

is within operating range again (a lockout reset is

necessary).

The CH return sensor is damaged. Replace the CH return sensor.

A44

CH return sensor out of normal operating range

(open circuit)

The CH return sensor is damaged. Replace the CH return sensor.

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2. BLOCKING ERROR CODES

The boiler controller also recognises fault situations that can block the heat demands but do not lead to lockout condition. When the error condition

becomes resolved, the error will disappear but will also be written into the history data. In some cases the Auto Detection function can resolve the problem,

if there is no logical reason for the error or communication error detected.

Hold the button labelled “-” on the central heating adjustment side (display, front panel) down for at least 3 seconds, then conrm the number of burner

units.

ERROR

CODE

MEANING POSSIBLE CAUSE SOLUTION

E7

TTB Exhaust Protection

Description:

The temperature measured on the TTB exhaust sensor is

too high. The TTB ‘trip point’ is the value which denes the

high limit of the exhaust gas. The limit changes depending on

burner load.

a) Air-fuel ratio has changed.

b) Water ow is not sufcient in

the heat exchanger.

c) Heat exchanger has a low limit

water level.

a) Find the cause of the problem and re-commission

the boiler.

b) Investigate the causes of the insufcient ow and

correct the faults before restarting the boiler.

c) Check that the automatic air vent on the heat

exchanger works correctly and the water pressure

is within acceptable range

E8

MaxSys Controller Error

Description:

During normal operation of the ignition controller, the ame

circuit is regularly checked. If the check fails, Error 8 will be

set.

Internal circuit error. a) Perform a power cycle (Disconnect and reconnect

the power supply)

b) If problem persists, then replace the MaxSys

controller.

E21 MaxSys Controller Hardware Error Replace the MaxSys controller.

E25 Software Communication Error. Refer to manufacturer.

E32

DHW sensor out of normal operating range (short circuit)

Description:

This condition will inhibit DHW demand. The boiler can still

enter CH mode.

The DHW sensor is damaged. Replace the DHW sensor.

E33

DHW sensor out of normal operating range

(open circuit)

Description:

This condition will inhibit DHW demand. The boiler can still

enter CH mode.

The DHW sensor is damaged. Replace the DHW sensor.

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ERROR

CODE

MEANING POSSIBLE CAUSE SOLUTION

E34 Low Voltage Error

Low Mains voltage will trigger this

error (below 167 V).

Investigate the reason for low voltage supply.

Re-establish correct voltage.

E37 Low Water Pressure

The water pressure is insufcient. Investigate the cause of the water pressure drop and

restart the boiler.

E41

Water Pressure Signal Time-Out.

Description:

The water pressure value is not refreshed often enough.

Loose link wire on the MaxSys

controller.

Check & re-secure wiring connections.

E45

TTB sensor* out of normal operating range (short

circuit)

Loose link wire on the MaxSys

controller.

Check & re-secure wiring connections.

E46

TTB sensor* out of normal operating range

(open circuit).

Loose link wire on the MaxSys

controller.

Check & re-secure wiring connections.

E47 Water Pressure Sensor* Error

Loose link wire on the MaxSys

controller.

Check & re-secure wiring connections.

E74

Solar sensor* out of normal operating range

(short circuit)

Loose link wire on the MaxSys

controller.

Check & re-secure wiring connections.

E75

Solar sensor out of normal operating range

open circuit

Internal error in the MaxSys

controller.

Replace the MaxSys controller.

E76

Gas Pressure Error

Description:

If the Gas Pressure Switch opens at any time for more than

5 s, Error 76 is generated and will switch off the system.

a) The Gas Pressure Switch is

faulty.

b) The gas pressure is too low.

a) Replace the Gas Pressure Switch.

b) Investigate and x gas supply.

E77 Condensate High Pressure (Blockage)

The condensate pipe has been

blocked and the water level has

risen to an unsafe level in the

heat exchanger.

Clear out the condensate piping system.

E78 Flapper does not open

a) A foreign body, or built up

contamination within the APS

apper house has built up.

b) The airway on the Venturi is

completely blocked.

a) Clean the APS apper housing. If the problem

persists, then change the APS apper housing.

b) Remove the obstruction from the airway.

* Not currently used in standard FHE setup

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ERROR

CODE

MEANING POSSIBLE CAUSE SOLUTION

E79 Flapper does not close

A foreign body, or built up

contamination within the APS

apper house is present.

Clean the APS apper housing. If the problem

persists, then change the APS apper housing.

E81

Drift Test Warning

Description:

Temperature difference between CH Supply and CH

Return Sensors are monitored to detect micro crack in

the sensors.

a) Micro crack has developed on

the CH Supply Sensor, or the

CH Return Sensor.

b) Large electromagnetic eld is

affecting the electrical circuit.

c) Wire connections are loose.

a) Replace the damaged sensor

b) Investigate for electromagnetic disturbances

c) Replace the relevant wire loom in the boiler

E90 Communication Error Refer to manufacturer (Honeywell).

E94 DSP Firmware Problem

DSP has encountered serious

internal problem due to corrupted

content of non-volatile memory.

Replace DSP device.

E95 Cascade CH Supply Sensor Error.

There is no relevant data about

CH supply temperature coming

from the Controller, or the

Cascade Sensor.

Check connection of CH supply sensor on the boiler

body and the Cascade sensor in the pipeline.

E96 Outside Temperature Sensor (OTC) Error.

OTC control is activated by

sending OTC curve to non-zero

value and Outside Temperature

Sensor is not present

(open/short).

Check connection of Outside Temperature Sensor to

master DSP if OTC is used. Check if OTC curve is set

to zero when OTC is not used in the system.

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E97 Cascade Structure Mismatch

Cascade depth (count of DSP

devices) has been changed.

The total count of reported

MAXSYS devices has been

changed.

Cascade structure has been

changed, some units’ DSP or

MAXSYS has been added or

removed.

Order of DSP connections in

chain has been changed.

Cascade has mixed structure with

non-equal count of burners per

DSP.

Last Auto Detection failed.

For further information on boiler

cascade, see Section 2.19.1.

Check if the order of DSPs has not been changed.

If cascade structure has been changed, re-do Auto

Detection.

Perform Auto Detection again

E98 Communication Error between two DSPs

There is missing communication

between two DSP boards due to

wiring, power supply problems or

board problems.

Cascade structure has been

changed, some units with DSP

have been removed.

Order of DSP connections in

chain has been changed.

Check cables and fuses related to affected DSP

device. If not successful, replace DSP board. Check

neighbouring MAXSYS devices for problems with

power supply or communication.

If cascade structure has been changed, re-do Auto

Detection.

Note: This error message is shown on the master DSP with indication of nearest affected burner as well as on the slave DSP affected - either on the one which has

lost it’s slave or on the second one which has lost it’s master.

FHE-250 MANUAL 09 2014 ISSUE 2

Page 61

4

ERROR

CODE

MEANING POSSIBLE CAUSE SOLUTION

E99

Communication error between DSP and MAXSYS. Some MAXSYS boards are not

responding to DSP queries. There

might be a broken

communication cable, broken

power supply cable or fuse or

MAXSYS or DSP device has fatal

internal failure.

Cascade structure has been

changed, some DSP has lower

number of MAXSYS

connected.

Check cables and fuses related to affected MAXSYS

device. If unsuccessful, replace MAXSYS and/or DSP

board.

If cascade structure has been changed, re-do Auto

Detection.

FHE-250 MANUAL 09 2014 ISSUE 2

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4

This log should be completed regularly as a record of boiler maintenance.

Date Action Remarks Sig.

4.14

MAINTENANCE LOG

FHE-250 MANUAL 09 2014 ISSUE 2

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4

This log should be completed regularly as a record of boiler maintenance.

Date Action Remarks Sig.

FHE-250 MANUAL 09 2014 ISSUE 2

Page 64

FHE-250 MANUAL 09 2014 ISSUE 2

Page 65

5

D

E

A

H

K

F

Q

N

J

M

G

P

L

C

B

SECTION 5 - GENERAL DATA

FIG.12 BOILER DIMENSIONS

5.1

BOILER DIMENSIONS

Note: Dimensions are for one FHE-250 model, further models (if being cascaded) would be stacked vertically or horizontally.

Adjust dimensions, according to number of models being cascaded.

Dimensions mm
Dimensions are approximate and only intended as a guide to aid installation.

MODEL: FHE 250

A

Overall Width 650

B

Overall Depth 1420

C

Cabinet Depth 1360

D

Cabinet Height 785

E

Adjustable Foot Height 35 ± 10

F

Gas Inlet Height 160

G

Gas Inlet Distance From Edge 520

H

Flue Outlet Height 608

J

Flue Outlet Distance From Edge 407

K

Flow Pipe Height 270

L

Flow Pipe Distance From Edge 140

M

Return Pipe Height 475

N

Return Pipe Distance From Edge 140

P

Condensate Pipe Height 155

Q

Condensate Pipe Distance From Edge 155

FHE-250 MANUAL 09 2014 ISSUE 2

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5

MODEL: FHE

UNIT 250 500 750 1000

The FHE-250 has been designed and manufactured to the following standards:
BS EN 60335:2012, BS 6644:2011, BS EN 15420:2010, BS EN 15417:2006, BS EN 656:2000,
BS EN 61000-4:2010, BS EN 55014-1:2006, BS EN 50371:2002, BS EN 55014-2:1997,

and complies with the following Directives:
2009/142/EC - the Gas Appliances Directive
2006/95/EC - the Low Voltage Directive
2004/108/EC - the Electromagnetic Compatibility Directive

92/42/EEC - the Boiler Efciency Directive

General

Output kW 250 500 750 1000
Gas Input (Gross) kW 255.1 510.2 765.3 1020.4
Minimum Flow Rate * L/s 1.25 1.25 1.25 1.25
Turn Down 1:6 1:12 1:18 1:24

Efciencies

Condensing Efciency (50°C Output, 30°C Return) ** % 108.9 108.9 108.9 108.9
Non-Condensing Efciency (80°C Output, 60°C Return) ** % 97.1 97.1 97.1 97.1

Weight

Shipping Weight kg 150 300 450 600
Operational Weight kg 170 340 510 680
Water Content L 15 30 45 60

Pressure

Minimum Gas Pressure mbar 5 5 5 5
Maximum Gas Pressure mbar 200 200 200 200
Minimum Water Pressure barg 1 1 1 1
Maximum Water Pressure barg 6 6 6 6
Hydraulic Pressure Drop Per Boiler kPa 45 45 45 45

Temperature

Heating Circuit Minimum Temperature °C 5 5 5 5
Heating Circuit Maximum Temperature °C 95 95 95 95

Ventilation Requirements for Combustion Purposes (Free Area)

Low Level inlet cm

2

1545 2820 4095 5370

High Level Outlet cm

2

773 1410 2048 2685

Electrical Requirements

Boiler Electrical Supply V 230 230 230 230
Power Consumption: Boiler Only W 350 700 1050 1400
Fuse Rating A 5 13 13 13

Connection Sizes All threads BSP F= Female, M=Male

Flue Outlet mm 150 2 x 150 3 x 150 4 x 150
Gas Inlet mm 28 2 x 28 3 x 28 4 x 28
Flow Pipe DN 50 2 x 50 3 x 50 4 x 50
Return Pipe DN 50 2 x 50 3 x 50 4 x 50

TI 127 ISSUE 6 03 2013

Gas Consumption Rate: 4 to 24.5 m3/hr

Flue Gas Conditions:

Volumetric owrate = 107.6 m3/hr

CO2 Content = 9.5 ± 2.5%
Maximum Temperature = 98.5°C

Boiler Part Load Efciency: 101% nett.

5.2

BOILER SPECIFICATION

Up to 12 FHE-250 models can be cascaded, allowing a total output of 3000 kW. For simplicity,
250 - 1000 kW models are shown below, more details on request.

Note:

* Figures quoted are for a single boiler module running at

minimum output (41.66 kW) at a 8 °C

temperature differential between ow and return.

** Figures quoted are nett efciencies.

FHE-250 MANUAL 09 2014 ISSUE 2

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5

5.3

SEASONAL EFFICIENCIES

C.I.B.S.E. Method

100.3% Net Efciency : "A" Rated

Boiler Rating Label Seasonal Efciency Range (net efciency)

A > 96

B 93 – 96

C 90 – 93

D 87 – 90

E < 87

HM Government Non-Domestic Building Services Compliance Guide Method

94.2% Gross Efciency : "A" Rated

90% and above

86% - 90%

82% - 86%

78% - 82%

74% - 78%

B

C

D

E

F

70% - 74%

Below 70%

G

A

A

FHE-250 MANUAL 09 2014 ISSUE 2

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5

!

IMPORTANT

Recommended Water Conditions

It is very important that a strict water management program is followed to ensure trouble free boiler

operation.

The following are recommended for feedwater/boiler water

pH Value 8.5 to 9.5 tested at room temperature.
Hardness less than 2.0 mg/kg in the form of CaCO

3

Suspended Solids None
Chloride Less than 50 mg/kg
Organic Matter Less than 5 mg/kg
Oil None

Silica Less than 180 mg/kg, in the form of SiO

2

mg/kg = Milligrams per Kilogram
CaCO

3

= Calcium Carbonate

SiO

2

= Silicon Dioxide

For practical purposes mg/kg = ppm

5.4

RECOMMENDED WATER CONDITIONS

FHE-250 MANUAL 09 2014 ISSUE 2

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5

FIG. 13 NAME PLATES

5.5

NAME PLATES

FHE-250 MANUAL 09 2014 ISSUE 2

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5

FULTON CONDENSING BOILER

MODEL FHE250

COUNTRY OF
DESTINATION:

GAS CATEGORY:

GAS TYPE:

GAS SUPPLY PRESSURE: 20 mbar

WARNING

• THIS BOILER MAY ONLY BE INSTALLED IN A ROOM WHICH COMPLIES WITH THE APPROPRIATE VENTILATION
REQUIREMENTS AND WHICH IS SEPARATED FROM LIVING ROOMS

• READ THE INSTALLATION INSTRUCTIONS BEFORE INSTALLING THE BOILER

• READ THE USER’S INSTRUCTIONS BEFORE LIGHTING THE BOILER

5.6

BOILER PACKAGING LABEL

For each boiler name plate and packaging, the following information will be completed,
based on the country of destination:

Country of destination: AT, CH, CZ, DK, EE, ES, FI, GB, HU, IE, IT, LT, LV, NO, PT, RO, SE, SI, SK

Gas category: I

2H

Gas type: G20

Country of destination: FR, DE, BE, LU, PL, RO

Gas category: I

2E

, I2Er, I2E(R)

Gas type: G25 & G231

Country of destination: NL

Gas category: I

2L

Gas type: G25, G26 & G27

FHE-250 MANUAL 09 2014 ISSUE 2

Fulton Ltd

Material & Workmanship Warranty

General Warranty

The Fulton general Guarantee is given in lieu of
and in exclusion of any warranty expressed or
implied, statutory or otherwise, as to the state,

condition, performance, quality or tness of the

goods. Save thereunder we shall be under no
obligation or liability of any kind to you in regard

to the goods. In the case of new goods
manufactured and supplied by us we will make

good any defect developing therein under proper
use within 12 months of delivery, provided that
after investigation in our sole discretion we are

satised that the defect arose from faulty design,

materials or workmanship and from no other
cause whatsoever.

Defective goods or parts must be returned to us
as soon as possible after discovery of the defect,
Costs of carriage and of detaching and
incorporating parts will be borne by you. ln all
cases at the termination of such 12 months all
liability on our part will cease.
No liability whatsoever is to be incurred by us
in respect of gauge or sight-glasses, packing
glands or electric motors or any goods or

accessories not of our manufacture. But so far as

we are able, we shall let you have the benet of

any guarantee or warranty given to us in respect
thereof.

2 Year Warranty

On the Fulton Boiler Pressure Vessel

Fulton Ltd will repair or replace EXW Bristol factory any parts which within two (2) years of the date

of delivery is found to be defective in workmanship, or material, provided this equipment is operated

and maintained by the buyer for the purpose for which it was designed and in accordance with the

Manufacturer’s Handbook. This Warranty does not cover damage or failures that can be attributed

to corrosion, scale or dirt accumulation or to low water conditions. This Warranty is good only in the

United Kingdom of Great Britain and Northern Ireland.

This Warranty does not include labour or delivery charges of any kind.

FHE-250 MANUAL 09 2014 ISSUE 2

Fulton Ltd

5 Fernhurst Road
Fishponds
Bristol
BS5 7FG
England

Telephone: [phone]
Fax: [phone]

Email: [e-mail]

www.fulton.co.uk