Fulton Pulse HW Fully Condensing Hydronic Boiler User Manual

INSTALLATION AND

OPERATION MANUAL

Gas Pulse Combustion

Hydronic Heating Boiler (PHW)

Serial/National Board #

Model

Fulton Order

Sold To

Job Name

Date

PHW-IOM-2013-0214

PHW-IOM-2013-0214 TABLE OF CONTENTS

Introduction 1-1

Overview .............................................................................................................. 1-2

Warnings & Cautions ............................................................................................1-2

Disclaimers and Local Codes ................................................................................1-2

Installation 2-1

Product Overview ................................................................................................. 2-2

Review Shipment Contents .................................................................................. 2-2

Placement & Rigging ........................................................................................... 2-3

Clearances and Serviceability ..............................................................................2-5

Install Isolation Mounts ....................................................................................... 2-5

HOW TO INSTALL ELASTOMER CUBE ISOLATION MOUNTS ........................................................25

HOW TO INSTALL SPRING ISOLATION MOUNTS .........................................................................26

HOW TO INSTALL SEISMIC SPRING ISOLATION MOUNTS...........................................................27

Install Boiler Trim .................................................................................................2-8

Water Chemistry Requirements ...........................................................................2-8

Install Water Piping .............................................................................................. 2-9

Install Condensate Drain .................................................................................... 2-11

INSTALL CONDENSATE DRAIN PIPING .....................................................................................212

Install pH Neutralization Kit ...............................................................................2-12

Install Gas Piping ................................................................................................2-14

Install Field Wiring .............................................................................................2-14

Air Intake Supply Piping Installation Preparation .............................................. 2-15

CEMENTING JOINTS ...................................................................................................................216

Install Intake Mu er ......................................................................................... 2-17

Preparing to Install Exhaust Vent Piping ............................................................2-17

Exhaust Mu er Installation ..............................................................................2-18

Air Intake & Exhaust Piping Requirements for the Pulse Boiler ........................2-19

Air Intake Supply and Exhaust Vent Installation ...............................................2-20

Vertical Vent Flashing and Installation .............................................................. 2-21

Vertical Vent Termination ..................................................................................2-21

Horizontal Installation Wall Penetrations ......................................................... 2-24

Wall Thimble Installation .................................................................................. 2-24

Horizontal Vent Termination ............................................................................. 2-25

After Installation/Prior to Start-Up .................................................................... 2-26

Installation Checkpoints ...................................................................................2-28

Testing Ignition Safety Shut O ........................................................................2-28

Measure Gas Flow Rate ..................................................................................... 2-28

TO CORRECT INPUT  ADJUST GAS PRESSURE REGULATOR ....................................................229

Rating the Boiler ................................................................................................2-29

To Check for High Gas Pressure ..........................................................................2-29

For High Gas Pressure Installations Using Fisher Regulators .............................2-29

Before Leaving the Installation ......................................................................... 2-30

Operation 3-1

Before Start Up .....................................................................................................3-2

Start Up ................................................................................................................3-2

LINKAGE ADJUSTMENT FOR PULSE MODULATED BOILERS.......................................................33

IF THE BOILER DOESN’T START ..................................................................................................35

Sequence of Operation for Modulated Pulse Hydronic Boilers ............................ 3-6

General Operation of the Boiler ........................................................................... 3-6

Programming Instructions for the SOLA Control ................................................. 3-6

CHANGING/TESTING SOLA HIGH LIMIT SETPOINT ..................................................................310

VERIFYING CHANGES TO HIGH LIMIT SETPOINT .....................................................................310

ACCESSING LOCKOUT HISTORY AND CLEARING LOCKOUTS .....................................................311

PROCEDURE FOR REMOTE FIRING RATE USING A 420MA SIGNAL SINGLE BOILER ...........312

PROCEDURE FOR REMOTE SETPOINT USING A 420MA SIGNAL SINGLE BOILER ................313

PROCEDURE FOR LEAD/LAG WITH OUTDOOR RESET WITH MULTIPLE BOILERS ....................314

SINGLE BOILER OUTDOOR RESET PROGRAMMING ..................................................................318

Third Party SOLA Control ....................................................................................3-21

LEAD/LAG OUTDOOR RESET CONFIGURATION USING COMMUNICATION PORT 2 ..................321

STAND ALONE BOILERS CONTROLLED BY A THIRD PARTY CONTROL ......................................321

GATEWAYS .................................................................................................................................321

Maintenance 4-1

General ................................................................................................................. 4-2

Daily Maintenance and Inspection Schedule ......................................................4-2

Monthly Maintenance and Inspection Schedule .................................................4-2

Annual Maintenance and Inspection Schedule ................................................... 4-3

After All Repairs and Maintenance ...................................................................... 4-4

Troubleshooting ...................................................................................................4-5

Reviewing Diagnostics on SOLA Control ..............................................................4-6

TAKING SCREEN SHOTS................................................................................................................47

Warranty & Parts 5-1

Standard Warranty for Fulton Pulse Boilers

with Carbon Steel Exhaust Pipes .......................................................................... 5-2

Standard Warranty for Fulton Pulse Boilers

with Duplex Stainless Steel Exhaust Pipes ...........................................................5-3

Parts ..................................................................................................................... 5-4

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

0-1

TABLE OF CONTENTS PHW-IOM-2013-0214

0-2

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

1-1

INTRODUCTION PHW-IOM-2013-0214 SECTION 1

Overview

Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:

§ Material inspections

§ Manufacturing process inspections

§ American Society of Mechanical Engineers (ASME)

welding inspection

§ ASME hydrostatic test inspection

§ Electrical components inspection

§ Operating test

§ Final engineering inspection

§ Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta responsible for the operation of the boiler. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, quali ed installers and service personnel. Trained personnel are responsible

for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are quali ed and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training speci c to this product.

Warnings & Cautions

WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS.

§ 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 e ectiveness.

All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.

Disclaimers and Local Codes

Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, in the US to the National Fuel Gas Code ANSI Z2231/NFPA 54 latest edition, and the speci c instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.

When required by local codes, the installation must conform to the American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section IV for a maximum allowable working pressure of 160 psig. Maximum allowable working temperature varies by design (210 F for duplex; 240 F for carbon).

When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jurisdictional authorities prior to installation.

1-2

INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-1

INSTALLATION PHW-IOM-2013-0214 SECTION 2

This Boiler is a Direct Vent Boiler for Installations on Non-Combustible Floors Only

Fulton Gas Fired Pulse Combustion Boiler

Manufactured by

Fulton Heating Solutions, Inc.

Pulaski, New York 13142

Maximum Gas Supply Pressure: 14 Inches W.C.

Minimum Permissible Gas Supply Pressure for Purpose of Input Adjustment: 7 Inches W.C. 11 Inches W.C.

Electrical Ratings: 120 V/60 Hz/Less than 15 Amps

Conforms to ANSI Std. Z21.13 __________

Certified to CSA Std. 4.9__________

Wall Thickness Through Which Vent System May Be Installed: 3

/4 Inches Min. / 20 Inches Max.

Minimum Clearance to Combustibles: 1 Inch (Sides) / 24 Inches (Top, Front & Rear)

Type of Gas:

Natural Propane

Boiler Model No.

Boiler National Board No.

Year

Min. BTU Input/Hr. Min. BTU Output/Hr.

Max. BTU Input/Hr. Max. BTU Output/Hr.

Design Pressure PSI

Mimimum Relief Valve Capacity: Pounds/Hr.

Manifold Gas Pressure: Inches W.C.

! WARNING

All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

4 CAUTION

This boiler is certi ed for indoor installation only.

This boiler is not designed for use in systems where water is continuously replenished. Mineral build-up may occur on the heat transfer surfaces and result in overheating and possible heat exchange failure. The warranty is valid for closed loop systems only.

Fulton cannot be held responsible for the selection, engineering, installation, or sizing of any additional equipment or components of the hydronic heating system.

This boiler, when installed in conjunction with a refrigeration system, must be installed so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. 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 systems must be equipped with  ow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.

2-2

Product Overview

Prior to the performance of installation, operation, or maintenance procedures, personnel should become familiar with the equipment (Table 1, Figures 1 and 2) and its components.

The Fulton Pulse combustion hydronic boiler is an automatic gas  red, direct vent boiler. This boiler utilizes pulse combustion principle. It does not have conventional burner controls or chimney. The combustion components are of integral design with the heat exchanger. Each boiler is built to ASME and CSD-1 Codes, hydrostatically tested, test  red, and shipped as a complete packaged unit.

All installations must be in accordance with the American National Standard “National Fuel Gas Code,” latest edition, and with the requirements of local utilities or other authorities having jurisdiction. Such applicable requirements take precedence over the general instructions herein.

Since an external electrical source is utilized, the boiler must be electrically grounded in accordance

FIGURE 1  PULSE BOILER PLATE

with the National Electrical Code, ANSI/NFPA 70-latest edition.

In some cases the approval authority may insist that the installation conform to the American Society of Mechanical Engineers ASME safety standard for controls and safety devices for automatically  red boilers, or CSD-1. In Canada, gas installations must be in accordance with the current CAN/CGA B149.1 and .2 and/ or local codes. Electrical installations must be installed in accordance with the current CSA C22.1 Canadian Electrical Code and/or local codes.

Review Shipment Contents

Your Fulton Pulse Boiler shipment should be fully reviewed upon receipt. The following are standard and accessory items that may be included with your shipment.

The customer should also examine the equipment for any shipment damage. It is the responsibility of the installer to ensure all parts supplied with the equipment are  tted in a correct and safe manner.

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

} STANDARD TRIM

The following items are standard trim for Fulton Pulse Combustion Hydronic Boilers:

§ Microprocessor Based Control - 120 volt with built-in operating and high

limit controls, and separately wired dual element sensor

§ Low Water Cuto (Probe Type)

§ Control Panel Completely Wired with Diagram

§ Gas Pressure Switches

§ Spark Ignition

§ Factory-Assembled and Mounted Fuel Train

§ Flame Rod

} PACKAGED SEPARATELY

Included with and packaged separately with each boiler are the following components:

§ ASME Pressure Relief Valve

§ Pressure-Temperature Gauge

§ Air Intake Pipe Adaptor

§ Installation, Operation, and Maintenance Manual

§ Elastomer Coated Fiberglass Cubes or Springs For Mounting

§ Gas and Water Flex Connectors

§ Intake and Exhaust Mu ers

§ 1 Can Touch-up Paint

} OTHER ACCESSORIES

Other items that may be included are:

§ Condensate Drain - one condensate drain kit can accommodate the

condensate from up to 12 MM BTUs.

§ PH Neutralization Kit

! WARNING

Competent personnel in accordance with all applicable local codes should carry out the installation of the Fulton equipment. All state and jurisdictional codes beyond the scope of the applicable ASME Boiler and Pressure Vessel Codes, for its corresponding classi cation, should be followed in all cases. Jurisdictional authorities must be consulted prior to installation.

A competent rigger experienced in handling heavy equipment should handle rigging your equipment into position.

The equipment must be installed on a non-combustible surface.

Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions exist.

Placement & Rigging

Proper placement of your Fulton product is essential. Correct placement is the  rst step to trouble-free installation, operation, and maintenance.

Adhere to the following for placement and rigging:

1. Check building speci cations for permissible  oor loading. Use Table 1 for unit reference.

2. Conform to all the requirements of all national, state and local codes established by the authorities having jurisdiction and/or the U.S. to the National Fuel Gas Code, latest edition. Authorities having jurisdiction should be consulted before installations are made. Where required by local codes, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers (ASME CSD-1).

3. Since an external electrical source is utilized, the boiler, when installed, must be electrically ground in accordance with the National Electric Code,

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

Failure to provide proper minimum clearances between equipment and combustible materials may result in  re.

4 CAUTION

Do not allow weight to bear on equipment

components to prevent damage.

2-3

INSTALLATION PHW-IOM-2013-0214 SECTION 2

Back View

Front View

Top View

I J

TABLE 1 - BOILER DIMENSIONS AND OPERATING REQUIREMENTS

Model PHW 300 500 750 1000 1400 2000

Speci cations

Input BTU/Hr 300,000 500,000 750,000 1,000,000 1,400,000 2,000,000

Nat. Gas consumption @ rated capacity

Propane Consumption @rated capacity

Electrical Requirements 120V/60/1 4.2/0.6 4.2/0.6 4.2/0.6 4.2/0.6 4.2/0.6 10/.75

(Amps: Max/Run)

MAWP PSI 160 160 160 160 160 160

Water Content Gal 34 34 42 42 80 75

Dry Weight LB 1395 1395 1800 1800 2230 2900

Operating Weight LB 1680 1680 2150 2150 3195 3500

Dimensions

A. Boiler Width IN 27.5 27.5 27.5 27.5 33.6 33.6

B. Overall Boiler Height IN 71.25 71.25 83.2 83.2 88.1 89

C. Overall Boiler Depth IN 53.25 53.25 51.3 51.3 62.6 70.1

D. Exhaust Outlet Diameter IN 4 4 4 4 4 6

E. Air Inlet Diameter IN 3 3 4 4 4 6

F. Water Inlet/ Outlet Diameter IN 2 2 2 2 2.5 4 Flanged

G. Min. Clearance to Ceiling IN 24 24 24 24 24 24

H. Min. Clearance to Either Side Wall IN 1 1 1 1 1 1

I. Min. Clearance in Front of Boiler IN 36 36 36 36 36 36

J. Min. Clearance Behind Boiler IN 24 24 24 24 24 24

FT3/Hr 300 500 750 1000 1400 2000

FT3/Hr 120 200 300 400 560 720

240V/60/1 2.1/0.3 2.1/0.3 2.1/0.3 2.1/0.3 2.1/0.3 5/0.4

BAR 4.1/11.0 4.1/11.0 4.1/11.0 4.1/11.0 4.1/11.0 4.1/11.0

FIGURE 2 -PULSE COMBUSTION HYDRONIC BOILER

2-4

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

American National Standards Institute (ANSI) National Fire Protection Association (NFPA) 70, latest edition.

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

5. Install on a level, non-combustible surface in the vertical position. Concrete is strongly recommended.

6. Provide combustion and ventilation air in accordance with applicable provisions of local building codes or: USA – NFPA 54/ANSI Z223.1, Section

5.3, Air for Combustion and Ventilation.

7. Locate the boiler so that the air supply and exhaust piping between the boiler and outside wall/roof are within length or pressure drop requirements. See Clearances and Serviceability section of this manual.

Clearances and Serviceability

Adhere to the following for clearances and serviceability:

1. All local and national codes (NFPA, ANSI, UL, ETL, ASME, CSA) must be followed for proper clearances and serviceability for your boiler or heater. Authorities having jurisdiction should be consulted before installations are made.

! WARNING

Do not install this boiler in an uncontrolled environment where condensate will be subject to freezing temperatures.

4 CAUTION

Do not install this boiler on carpeting.

Install boiler such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service.

2. Appropriate front, back, side and top clearances must be maintained (Figure 2, Table 1). This will allow access around the equipment to facilitate maintenance and a safe work environment. An 1 inch (25.4 mm) side

clearance is acceptable between boilers. Custom con gurations may not allow 1 inch (25.4 mm) side clearance.

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

Install Isolation Mounts

All pulse combustion boilers must be installed with vibration isolators. No

pulse combustion boiler shall be lagged directly to the concrete  oor due to the transfer of vibration. For installations near “sensitive” areas such as o ces, classrooms, or hospital rooms, spring mounts - which  t under the corner of each boiler - must be used instead of the cubes.

¡ How to Install Elastomer Cube Isolation Mounts

Adhere to the following for elastomer cube isolation mounts (see Figure 3):

1. Locate in the box of trim shipped with each Pulse boiler the 4 elastomer cubes (3” x 3” x 2”) used for vibration isolation.

2. Insert these cubes under each foot of the boiler.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-5

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

4 CAUTION

Do not attempt to move the boiler laterally while it is supported on isolators. Bent or broken leveling bolts or springs, or damage to the neoprene bottom spring cap could result.

Do not install the boiler in an uncontrolled environment where the condensate will be subject to freezing temperatures.

NOTE: ´ Flex connectors must be installed on the gas supply, water inlet and

water outlet lines. Spring loaded pipe hangers should be used on the air inlet and the  ue gas vent.

NOTE: ´ Contact your Fulton Representative for vibration isolation packages

designed speci cally for your application.

FIGURE 3 - INSTALLING ELASTOMER CUBE ISOLATION MOUNTS

¡ How to Install Spring Isolation Mounts

Adhere to the following for Spring Isolation Mounts (see Figure 4):

1. Thread the leveling bolt into the top load plate of the spring until the head of the bolt is within 1/8” of the top load plate of the spring.

2. Coordinate the location of each isolator.

3. Remove the small cap screw and washer. Raise the boiler with jacks or similar tools. Do not attempt to raise the boiler via one lifting point, but lift evenly around the perimeter of the boiler). Slide the spring isolator under the boiler or mounting bracket with the bolt head on the underside of the bracket.

4. Insert the small cap screw through the bracket and thread into the top of the leveling bolt and tighten  nger tight.

5. Lower the boiler (evenly) onto the spring isolators. Do not overload any one isolator and take care not to push the boiler sideways.

6. Do not attempt to place all the weight on one spring, but distribute the load proportionately by adjusting each isolator in sequence.

7. Continue to adjust each leveling bolt (in sequence) until the boiler is at its proper height. When the boiler is  lled with water, the springs will compress approximately 1-2”.

2-6

8. Tighten the small cap screw, thus securing the spring isolator to the supported equipment and locking the leveling bolt against turning.

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

! WARNING

The discharge from the safety relief valve must be arranged to ensure no danger of scalding personnel, or equipment damage.

Provisions must be made to properly pipe the safety relief discharge away from the boiler to the point of discharge.

FIGURE 4 - INSTALLING SPRING ISOLATION MOUNTS

NOTE: ´ Do not attempt to move the boiler laterally while it is supported

on the isolators. If it is necessary to move the boiler remove the weight from the isolators by raising the boiler before moving. Failure to follow this procedure could result in bent or broken leveling bolts or springs, or damage to the neoprene bottom spring cap.

¡ How to Install Seismic Spring Isolation Mounts

Adhere to the following for installation of Seismic Spring Isolation Mounts (see Figure 5):

1. Thread the leveling bolt 1/2” into the top of the load cap.

2. Remove the lock nut and one washer from the top of the leveling bolt. Locate leveling nut as far down on leveling bolt as it will travel.

3. Coordinate the location of each isolator.

4. Place a one inch shim next to each bracket between the boiler and the

housekeeping pad or structural  oor. If an operating clearance of other than one inch is desired, use an appropriate size shim.

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.

Ensure all labels on the boiler are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.

Do not store or use gasoline or other  ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

5. Raise the boiler and slide the spring isolator under the equipment mounting bracket with the leveling nut and one washer on the under side of the bracket.

6. Lower the boiler onto the spring isolators taking care not to overload any one isolator and taking care not to push the boiler sideways.

7. Install second washer and lock nut one inch down from top of leveling bolt.

8. Turn the leveling nut in a counter-clockwise rotation until the boiler just touches the shim. The shim may now be removed. Proceed with adjustment of the other three isolators.

9. Tighten the lock nuts on the leveling bolts, thus bolting the spring to the boiler and locking the leveling bolt against turning.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-7

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

Discharge from the safety relief valve must be arranged so that there is no danger of scalding. When the safety relief valve is piped away from the boiler to the point of discharge, there must be provisions to properly drain the piping.

No shuto of any kind may be placed between the safety relief valve and the boiler, or on the discharge pipe between the safety relief valve and the atmosphere. Doing so may cause an accidental explosion from overpressure.

4 CAUTION

NOTE: ´ Do not attempt to move the isolators laterally with the weight of the

boiler on them. If it is necessary to move the boiler, remove the weight from the isolators by raising the equipment before moving.

FIGURE 5 - INSTALLING SEISMIC SPRING ISOLATION MOUNTS

Care needs to be taken to eliminate oxygen from the water system, as excess oxygen in the system will reduce the life of any boiler. The boiler warranty does not cover heat exchanger replacement due to oxygen contamination of boiler water.

Heat exchanger failure due to inappropriate water quality, foreign matter or debris damage is not covered under the warranty.

If the piping system attached to this unit will be chemically cleaned, the boiler must be disconnected from the system and a bypass installed so that the chemical cleaning solution does not circulate through the boiler.

Install Boiler Trim

Each boiler is supplied with a safety relief valve sized in accordance with ASME requirements.

Adhere to the following for installation:

1. Connect the safety relief valve to the coupling located in the top of the boiler. The safety relief valve must be installed with a 6” nipple (8” for PHW2000) between the boiler and the safety valve. The safety relief valve must always be installed in the vertical position. The discharge pipe shall be not less than the full area of the valve outlet. The discharge pipe shall be as short and straight as possible and so arranged as to avoid undue stress on the valve.

2. Install pressure-temperature gauge in the side port of a tee installed in the boiler water outlet. A tee is installed on the nipple.

Water Chemistry Requirements

All water supplies contain some amount of solids, dissolved gases and dissolved minerals. These materials may promote corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting on boiler performance, valve operation and general pipe longevity, each location must be analyzed and treated accordingly. The following are installation recommendations for “closed-loop” recirculating hot water heating systems.

2-8

1. Automatic pressure activated water make up valve with back ow preventer providing water to the system, not fed directly to the boiler, set to maintain:

§ Required NPSH for recirculating pump(s).

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

ADDITONAL BOILER (S)

HEATING SUPPLY MANIFOLD

ADDITIONAL BOILER (S)

HOT WATER STOP VALVE

TEMPERATURE PRESSURE GAUGE

OPERATING AND HIGH LIMIT AQUASTATS (INTERNAL)

ASME SAFETY VALVE

STOP VALVE

DRAIN CONDENSATE DRAIN

Multiple Boiler Installation

TYPICAL PIPING SYSTEM

UNLESS OTHERWISE NOTED, ALL

COMPONENTS SHOWN ARE TYPICAL

ON EACH BOILER

HEATING RETURN MANIFOLD

EXPANSION TANK

STOP VALVE

CHECK VALVE

PRESSURE REDUCING VALVE

MAKEUP WATER

AUTOMATIC AIR VENT

FLAME ROD SPARK PLUG

§ A positive system pressure at the highest point of 5 to

10 psi.

§ Make up water valve should be designed to add water

to the system at the outlet of the boiler and should not be fed directly into the boiler.

2. Air removal equipment, including air separator and automatic air breather valves.

3. A functioning expansion tank designed to system speci cations.

4. Filtration to remove particulates installed inline with the suction side of the recirculating pump.

5. Bypass chemical feeder for corrosion inhibitor maintenance.

6. Optionally a water meter could be installed in series with the automatic pressure activated water make up valve to monitor any make up water.

7. Ensure water quality meets the following:

§ Oxygen - less than 250 ppb (operating condition)

§ pH - must be in the range of 8-10

§ Total Iron & Copper - less than 25 ppm

§ Corrosion Inhibitor - level capable of maintaining

iron corrosion rates < 2 mpy. Due to changing environmental restrictions, a non-heavy metal, all organic inhibitor is recommended, which is designed for multi-metal systems including ferrous metals and yellow metals such as copper and brass.

§ Chlorides - less than 250 ppm as Cl. Limit applicable

only to installations utilizing duplex steel pressure vessel components.

Install Water Piping

The bottom connection to the boiler is the INLET and must be connected as the return from the system. The top connection on the boiler is the OUTLET and must be connected as the supply to the system.

FIGURE 6 - TYPICAL PIPING (MULTIPLE BOILER SYSTEM)

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2-9

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

Do not use matches, candles,  ame or other sources of ignition to check for gas leaks.

If the water supply must be temporarily disconnected from the condensate

trap, the boilers must be turned o to prevent accidental  ue gas emission into the boiler room. An uninterruptible

water supply is required and shall be connected to the ¼” compression  tting on the condensate drain. The water supply maintains a water level in the drain kit to prevent accidental  ue gas emission into the boiler room.

Adhere to the following for water piping installation (Figure 6):

1. Connect hot water supply to heating system feed line.

2. Connect expansion tank.

3. Connect return water to boiler return water connection.

4. Install an air separator and air eliminator (air vent) which is necessary as there is no built in boiler air eliminating feature.

5. If a sealed diaphragm-type expansion tank is used, install air eliminator in hot water piping at air separator.

6. If an air cushion type expansion tank is used, pipe tank directly into boiler supply.

7. On multi zoned systems (or a system with both space and domestic water heating), air elimination must be provided either in the common piping or every loop. When the boiler is installed at a higher level than baseboard radiation, air elimination must be provided directly above the unit.

8. Install hot water circulator, remote mounted from boiler. Do not attach directly to the boiler. Flexible connectors must be placed between the circulator and the boiler.

Cements for plastic pipe are  ammable liquids and should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors. Avoid contact of cement with skin and eyes.

4 CAUTION

Some soap used for leak testing is corrosive to certain types of metals. Clean all piping thoroughly after completing the leak check.

NOTE: ´ For all models, a no  ow condition will not damage the heat

exchanger, however, adequate  ow should be provided to prevent tripping the boiler on high temperature limit.

9. For boilers with carbon steel or duplex steel heat exchangers, the

maximum allowable temperature di erential across the heat exchanger is 100 degrees F. Minimum outlet temperature for carbon steel units must be 120 degrees F or greater. Maximum allowable working temperature for carbon steel units is 240 F. High limit is set at 230 F, therefore operating at a temperature greater than 220 F is not recommended. For duplex steel units, maximum allowable working temperature is 210 F. High limit is set at 200 F, therefore operating at a temperature greater than 190 F is not recommended.

10. Install manual purging valves in all loops and zones. Install pressure reducing (automatic  ll) valve in the cold water  ll line to the boiler system.

11. Check that the proposed operation of zone valves, zone circulator(s) and diverting valves will not isolate air separator(s) and/ or expansion tank(s) from the boiler.

12. Clearance from hot water pipes to combustibles must be at least 6”.

13. The boiler, when used in conjunction with a refrigeration system, must be installed so the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering the boiler. 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 systems shall be equipped with  ow control valves or other automatic means to prevent gravity circulation of the boiler water during

2-10

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

the cooling cycle.

14. The boiler is furnished with a probe type low water

cuto . No  eld piping is required. If the probe does not sense water, the boiler will shut down and a red indicator will be illuminated on the control panel.

15. The boiler is not provided with external drain connections. A drain valve must be installed near the inlet connection to the boiler and piped to a suitable  oor drain. A Boiler Drain Assembly can also be purchased from Fulton. This Boiler Drain Assembly must be installed near the inlet connection to the boiler.

16. Before  lling the boiler clean and  ush the system to remove any debris. Clean and  ush old piping thoroughly before installing the boiler. Consider installing a strainer ahead of the boiler.

Install Condensate Drain

The condensate drain kit is intended for use with any size Pulse unit supplied by Fulton. The 3/4” condensate drain on

the pulse unit will be connected to the 1” inlet on the drain kit. One or more drain lines may be connected to this inlet (maximum of 12 MM BTU/hr) through a common header. See Figure 7.

Adhere to the following for installation:

1. An uninterruptable water supply is required and shall be connected to the 1/4” compression  tting on the drain  oat. The water supply maintains a water level in the drain kit to prevent the  ue gas from entering the boiler room through the condensate connection. The 1 1/2” connection shall be piped to an appropriate drain for disposal. If the water supply must be temporarily disconnected, the boiler(s) must be turned o to prevent accidental  ue gas emission into the boiler room.

2. Keep the cover on at all times, except during maintenance of the drain. This drain should be monitored and checked regularly in your Pulse maintenance schedule.

3. A condensate collecting tank and condensate pump

FIGURE 7 - MULTIPLE BOILER CONDENSATE DRAIN INSTALLATION

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-11

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

DO NOT USE GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. If in doubt, contact your Fulton representative prior to operation.

Do not store or use gasoline or other

 ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances. Cements for plastic pipe should be kept away from all sources of ignition. Proper ventilation should be maintained to reduce the hazard and to minimize breathing of cement vapors.

will be required if a  oor drain is not available to discharge to (Collecting tank and pump are not supplied with the boiler). Complete condensate drain kits are available from Fulton.

¡ Install Condensate Drain Piping

Adhere to the following when installing condensate drain piping:

1. All piping must be galvanized or stainless steel and should be free of leaks.

2. Make sure either elastomer coated  berglass cubes or spring mounts have been installed under each leg of the boiler.

3. Install the condensate piping to the condensate drain in the lower right hand side of the boiler.

4. Connect 3/4” condensate drain(s) to the 1” header connected in a manifold.

The header must be at least 5 ½” below the condensate outlet of the

individual boiler and must remain  ooded by being at least 5 ½” below the outlet of the condensate drain trap..

5. Connect 1½” drain outlet to an appropriate waste line following applicable codes. The 1½” drain connection on the condensate drain must be the highest point prior to going to the drain. Failure to keep drain piping lower than this point will result in over ow of the condensate drain. Slope the drain pipe away at a minimum pitch of 1” for every 12 feet.

Do not attempt to start boiler to test wiring before  lling and purging the boiler. A dry  re will seriously damage the boiler and may result in property damage or personnel injury and is not covered by warranty.

4 CAUTION

The vent line connection on the gas pressure regulator must be piped in accordance with National Fuel Gas code, latest addenda. In Canada, gas installations must be in accordance with current CAN/CGA, and/or local codes.

6. Attach a 1/4” water supply to the compression  tting on the  oat. The water line must be connected to an uninterruptible supply. Fulton recommends connecting it before the “Fast-Fill” valve to the boiler supply but after the back  ow preventer to avoid contamination of a potable water supply. Maximum allowable water pressure to the compression  tting is 100 PSI.

Install pH Neutralization Kit

The pH Neutralization Kit is a Fulton-provided kit designed to bring the pH level of the boiler’s condensate to a neutral level. It is not a replacement or alternative for the Condensate Drain Trap. See Figure 8.

Adhere to the following for installation:

1. Use stainless or galvanized pipe and  ttings to connect condensate drain to kit.

2. Connect kit downstream of Condensate Drain Trap. See Figure 9.

3. Pipe outlet to appropriate drain.

NOTE: ´ Replacement bags are available from the Fulton Parts Department.

The medium in the container will neutralize the condensate of 12 MM Btu’s for approximately 6 months.

2-12

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

TOP VIEW

30 3/8

[771]

12 1/2

[318]

3 13/16

[97]

(TYP.)

FRONT VIEW

1 1/2" PLASTIC FITTING CONNECTION TO DRAIN

1" NPT

CONNECTION

TO BOILER

10 3/4

[273]

11 1/4 [286]

ISOMETRIC VIEW

FIGURE 8 - FULTON PH NEUTRALIZING KIT (WITHOUT PUMP)

FIGURE 9 - FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-13

INSTALLATION PHW-IOM-2013-0214 SECTION 2

FIGURE 10 - GAS VALVE CONFIGURATION

Install Gas Piping

Adhere to the following for gas piping installation:

1. Gas Piping should be installed in accordance with National Fuel Gas Code, ANSI Z223 1 1991 or latest addenda and any other local codes which may apply. In Canada gas installations must be in accordance with the current CAN/CGA B149.1 and .2 and/or local codes.

2. The pipe and the  ttings used should be new and free of dirt or other deposits. Piping must be of the proper size to insure adequate gas supply.

NOTE: ´ Do not use the boiler’s gas train inlet size as a

gauge for inlet piping size. Always refer to appropriate gas piping charts.

NOTE: ´ Full port ball valves approved for gas should be

used for gas isolation to reduce pressure drop.

3. Gas pressure to inlet of gas train should be 7” WC for natural gas and 11” WC for propane (PHW2000LE requires 11”WC on natural gas). Connect gas supply line to the open end of the tee on which the drip leg is installed. See Figure 10.

FIGURE 11 - FIELD WIRING

6. The boiler must be isolated from the gas supply piping

system by closing its individual manual shut o valve during any pressure testing of the gas supply system at more than 1/2psi (3.5kPa).

7. Gas vents to outdoor air must be provided for the gas pressure regulator. Restricting ori ces or bleed ori ces should not be used at anytime. The vent line connection on the gas pressure regulator must be piped to outdoor air by installer in accordance with the National Fuel Gas Code, ANSI Z223- 1-1991 or latest addenda.

8. In Canada gas installations must be in accordance with the current CAN/CGA B149.1 and .2 and/or local codes.

} HONEYWELL PRESSURE SWITCH

The Honeywell C6097 pressure switch is designed with internal vent limiters to meet UL 353 requirements and are CSA certi ed, UL listed, FM approved, and CSD-1 acceptable. Local codes may not permit a gas device (pressure switch) without an external vent line connection. If that is the case, a vent line must be added.

Install Field Wiring

4. When making gas piping joints, use a sealing compound resistant to the action of lique ed

petroleum gases. Do not use Te on tape on gas line threads.

5. 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.

2-14

Adhere to the following for  eld wiring installation (see Figures 11 and 52):

1. An independent power supply line is recommended for the boiler. Connect one 120 volt (60Hz) fused power line to terminal block to hot, or marked terminal per electrical diagram. Connect applicable wires to neutral and ground. Connect a ground wire to green colored ground lug in electrical control box.

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

2. Ensure gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service.

3. Any attempt to start the boiler to test wiring prior to  lling and purging may result in a dry  re and void the warranty.

Air Intake Supply Piping Installation Preparation

The boiler is equipped with air intake supply and exhaust vent connections located at the top and rear of the boiler respectively. See Figure 12. Air supply is on the top. For Models PHW300 and PHW500 these connections are 3” NPT threaded female  ttings and for Models PHW750, PHW950, PHW1000, and PHW1400 they are 4” NPT thread female  ttings. These  ttings will accept 3” and 4” male/female pipe to tubing adaptors respectively. Model PHW2000 has 6” NPT threaded female  tting. In supporting piping, or routing it through a rafter or wall, always use vibration eliminating hangers around the piping to prevent vibration transmission. Always avoid rigid connections between piping and structural members of the building.

1. For sealed combustion applications, air intake must be piped out of the building. Air Intake pipes and  ttings for all models shall be Schedule 40 PVC pipe. All Schedule 40 PVC pipe,  ttings, primer and cement must conform with American National Standard Institute and the American Society for Testing and Materials (ANSI/ASTM standards).

! WARNING

Do not attempt to start boiler to test

wiring before  lling and purging the boiler. A dry  re may cause injury, boiler damage, and/or property damage, and is not covered by warranty.

Do not use the boiler/burner as support for ducted air piping. Ducted piping must be supported independently of the boiler.

Do not terminate venting into an enclosed area.

2. For applications using make up air from the boiler room, a minimum of 10’

of venting including the intake mu er must be installed. Per ASME Section VI Para. 6.04, an unobstructed air ventilation opening should be sized on the basis of one square inch free area per 2000 BTU/HR maximum fuel input of the combined burners located in the boiler room. This is subject to state and local regulations. The installation of exhaust fans in a boiler room is not recommended.

Never use open  ame or smoke from a cigarette, cigar, or pipe as a testing method during boiler installation, operation, or maintenance.

Foreign substances, such as combustible volatiles in the combustion system can create hazardous conditions. If foreign substances can enter the air stream, the boiler combustion air inlet must be piped to an outside location.

Particulate matter or chemicals in the combustion air supply to the boiler will cause damage to air  apper gaskets, could cause the unit to fail to light, and is not covered under warranty.

FIGURE 12 - AIR INLET LOCATION

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-15

INSTALLATION PHW-IOM-2013-0214 SECTION 2

4 CAUTION

Intake PVC piping must be assembled using cement. This ensures that the intake is air tight and will not allow contaminants to enter the boiler from the boiler room.

Cement must be free- owing and contain no lumps, undissolved particles or any foreign matter that adversely a ects the joint strength or chemical resistance of the cement. The cement must show no gelation, strati cation, or separation that cannot be removed by stirring.

Cements for plastic pipe are  ammable and should be kept away from all sources of ignition. Proper ventilation must be maintained to prevent cement vapor hazards. Avoid contact with skin and eyes.

3. All alternative individual venting arrangements must result in an intake pressure drop not to exceed 2.5” w.c. (Consult factory for assistance.)

4. All common venting arrangements must result in a pressure drop of less than 0.1” w.c. in the common header. (Consult factory for assistance.)

NOTE: ´ Intake PVC piping must be assembled using cement. This will ensure

that the intake is air tight and will not allow contaminates from the boiler room into the boiler. The cement shall be free  owing and contain no lumps, undissolved particles or any foreign matter that adversely a ects the joint strength or chemical resistance of the cement. The cement shall not show gelation, strati cation, or separation that cannot be removed by stirring.

¡ Cementing Joints

Adhere to the following procedure (per ASTM D2855) (see Figure 13):

2-16

FIGURE 13 - AIR INTAKE BOILER CONNECTION

1. Measure and cut PVC pipe to desired length.

2. Chamfer end of pipe, removing any ridges or rough edges. If end is not chamfered, the edge of the pipe may remove cement from the  tting socket and result in a leaking joint.

3. Clean and dry surfaces to be joined.

4. Test  t joint and mark depth of  tting on the pipe.

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

5. Uniformly apply liberal coat of primer to inside socket surface of  tting and male end of pipe to depth of  tting socket.

6. Promptly apply solvent cement to end of pipe and inside socket surface of  tting. Cement should be applied lightly—but uniformly—to inside of socket. Take care to keep excess cement out of socket. Apply second coat to pipe end. Time is critical at this stage. Do not allow primer to dry before applying cement.

7. Immediately after applying last coat of cement to pipe, while inside socket surface and end of pipe are wet with cement, insert end of pipe into socket, turn pipe 1/4 turn to distribute cement evenly, continue to insert pipe until it bottoms out.

NOTE: ´ Assembly should be completed within 20 seconds after last

application of cement. Do not use hammer to insert pipe.

8. After assembly, wipe excess cement from pipe at end of  tting socket. A

properly made joint will show a bead around its entire perimeter. Any gaps may

indicate a defective assembly due to insu cient cement.

9. Handle joints carefully until completely set.

! WARNING

Install Intake Muﬄ er

To install intake mu er, cement joints as indicated in previous section. For best noise attenuation, the mu er should be installed as close to the boiler as possible, and can be horizontal or vertical in orientation.

Preparing to Install Exhaust Vent Piping

A Fulton Pulse boiler should not be connected to a common venting system with other types of gas appliances. Adhere to the following when preparing to install vent piping:

1. The boiler is equipped with an exhaust vent connection located at the rear of the boiler. For models PHW300 up through the PHW1400, the connection is 4” NPT threaded female. Model PHW2000, the connection is 6” NPT threaded female.

2. The exhaust line must be sloped down toward the boiler with a pitch of at least 1/4” per foot. Failure to do so can result in a condensate pocket which can result in an inoperative boiler. There must be no low spots in the exhaust pipe, as this can also result in a condensate pocket. A high spot is acceptable, provided the pitch from the high spot is maintained back to the boiler or to the outside point of the exhaust. In supporting piping, or routing it through a rafter or wall, always use vibration eliminating hangers around the piping to prevent vibration transmission. Always avoid rigid connections between piping and structural members of the building.

3. All alternative individual venting arrangements must result in an exhaust pressure drop not to exceed 2.5” w.c. (Consult factory for assistance.)

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-17

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

Crystalline silica may be present in components of this equipment. Exposure

to crystalline silica may pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines

o ered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

4 CAUTION

To prevent potential water damage, never leave an open manual air vent unattended.

4. All common venting arrangements must result in a pressure drop of -0.1” to 0.0” w.c if not using a draft assist fan. (Consult factory for assistance.)

5. All common venting arrangements must result in a pressure drop of

0.0” to 0.75” w.c. with the use of a draft assist fan. (Consult factory for assistance.)

6. Variable speed exhaust fan pressure setting should be no more than 0.1” w.c.

7. Flue vent pipes and  ttings for all Pulse boilers must be UL listed for use with Category IV, positive pressure, condensing equipment. Speci cally this material is AL294C. Stainless Steel 316L piping is also acceptable. At 480°F temperature rating, a 5” minimum air space clearance to combustibles is required. Applicable Federal Codes are NFPA 54/ANSI Z223.1 National Gas Code and NFPA/ANSI 211 Chimneys, Fireplaces, Vents and Solid Fuel Burning Appliances. In Canada, refer to the venting section of CAN/CGA B149.1 and 2. The gas vent installer should be familiar with these federal codes as well as any local codes and regulations that may apply. The procedure for adhesive joining stainless steel pipe and  ttings follows:

§ Do not mix stainless steel pipe with galvanized or other alternatives

for the entire length of the system.

§ All joints between sections of the vent connector and the vertical

conduit must be sealed with a high temperature sealant or gasket to

prevent any possible leakage of  ue gas.

§ Apply a bead of sealant, about 1/2“ in diameter, completely around

the male (without tabs) end of each conduit section or elbow, between 1/4” and 3/8” from the end of the section. Also run a similar sized bead down the seam weld of each section, from the edge of the pipe to the top of the bulge.

§ Fully insert the male end of the section into the female  tting of

the section below. Attach the sections together. Inspect the joint to

ensure that  ue gases will not escape. If necessary, apply additional sealant to any voids. Allow the sealant 24 hours to cure before operating the boiler.

§ See speci c manufacturers instructions for complete installation

details.

Exhaust Muﬄ er Installation

Adhere to the following for mu er drain installation:

2-18

§ For mu ers installed in the vertical con guration the drain can be

plugged.

§ For mu ers installed in the horizontal con guration, the drain opening

should be at the down slope (6 o’clock) position, and should be piped to the drain line between the boiler and the condensate drain. For best sound attenuation, the mu er should be installed as close to the boiler as possible.

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

Air Intake & Exhaust Piping Requirements for the Pulse Boiler

Adhere to the following for air intake and exhaust piping:

1. Use piping that matches the inlet/outlet connection sizes for the  rst 35 feet and 4 elbows closest to the boiler. See Tables 2 and 3.

§ The piping can be extended to 100 feet and 6 elbows by increasing the

pipe size to 6” for the PHW300 - PHW1000, and to 8” for the PHW2000.

§ For the PHW1400, the air intake and exhaust piping must be 4” for the  rst

10 feet and then piping must be upsized to 6” for up to 40 feet. If going beyond 40 feet, instead of upsizing to 6” after the  rst 10 feet, upsize to 8”.

§ It is acceptable to extend the piping up to 100 feet and 6 elbows with

proper sizing.

2. A minimum of 10 feet of piping is required on the air intake (even if taking combustion air from the boiler room) or exhaust. This creates the appropriate amount of backpressure for pulse combustion to operate properly.

! WARNING

3. If air intake or exhaust layouts require upsizing, keep the  rst 10 feel closest to the boiler matching the outlet connection size of the boiler.

4. If utilizing a common header pipe for multiple pulse boilers, the pressure drop across a common intake pipe must be neutral. The pressure drop across a common vent pipe must be between -0.1 and 0” W.C. if not utilizing a mechanical draft system.

5. Exhaust runs should, individually, not have pressure drops of more than

3.0” WC. Intake is +2.0”WC.

TABLE 2 - AIR INTAKE PIPING REQUIREMENTS

Model PHW Type Base

Diameter

(inches)

300 PVC 3

500 PVC 3

750 PVC 4

1000 PVC 4

1400* PVC 4

2000 PVC 6

Length (feet) Number of

90-degree

Elbows

10 minimum 35 maximum

0 4

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-19

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

Do not attempt to start boiler before

 lling and purging boiler heating system. A dry  re will seriously damage the boiler and may result in property damage or personnel injury and is not covered by warranty.

Operating the boiler beyond its design limits is dangerous and may also cause boiler damage. Do not attempt to upgrade boiler performance with unapproved modi cations.

TABLE 3 - EXHAUST VENT PIPING REQUIREMENTS

Model PHW Type Base

Diameter

(inches)

300 Stainless Steel

AL294C

500 Stainless Steel

AL294C

750 Stainless Steel

AL294C

1000 Stainless Steel

AL294C

1400* Stainless Steel

AL294C

2000 Stainless Steel

AL294C

*A minimum 10 feet of 4 inch air intake and exhaust is required for the PHW-1400. Air

intake and exhaust con gurations over 10 feet in length will require 4 inches for the  rst

10 feet from the boiler, and then 6 inches up to an additional 40 feet, and four elbows.

4 4

4 6

6 6

Length (feet) Number of

90-degree

Elbows

10 minimum

35 maximum

10 minimum

35 maximum

10 minimum

35 maximum

10 minimum

35 maximum

10 minimum

35 maximum

10 minimum

35 maximum

0 4

Air Intake Supply and Exhaust Vent Installation

Adhere to the following for air intake supply and exhaust vent installation:

1. Air intake supply and exhaust vent pipes and  ttings are suitable for vertical, through-the-roof or horizontal through-the-wall installation. The vent system must be installed in accordance with the manufacturer’s instructions.

2. All vent pipes and  ttings must be installed with appropriate 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. See Figure 14. 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.

3. The required minimum air space clearances also apply to electrical wires and any kind of building insulation away from gas vent and out of the required air space clearance.

4. Vertical runs or vent pipes and  ttings passing through  oors, ceilings, or in framed walls must be  re stopped at  oors and ceilings. The  re stop must close in the area between the outside of the vent and the opening in the structure. (Figure 15). When passing through a  oor or ceiling frame, provide an opening 5” to 9” air space clearance to vent pipe as applicable. The  re stop  ts to the bottom of a framed opening 13 1/4” square. Nail into the inside of the framed opening through the four holes in the ring. The  re stop is placed on top of a framed opening 14 1/4” square with the dished position down. Nail the  ange to the top of the framing.

2-20

+ 58 hidden pages

Fulton Pulse HW Fully Condensing Hydronic Boiler User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual