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

1

2

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

1

2

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

1

/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

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.

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

A

C

D

B

G

E

H

F

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

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

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)

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

2-9

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

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

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

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

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

DO NOT USE 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

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

Do not 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

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.

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

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.

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

3

500 PVC 3

3

750 PVC 4

4

1000 PVC 4

4

1400* PVC 4

6

2000 PVC 6

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

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

5. Pass the vent pipe through the opening in the  re stop. If used as a support, install the support ring around the vent pipe above the  re stop. Slide the support ring down to the top of the  re stop and tighten it securely to the vent pipe. Firestop supports can support up to 10 feet

of vent pipes and are recommended at all  oor and ceiling penetrations.

Figure 16. Air intake supply and exhaust vent pipes and  ttings must be securely supported.

6. Horizontal sections require supports every 5 feet and at elbows. From the boiler, all horizontal sections must rise at leas 1/4” per foot, and there must be no sags or dips where condensate could collect. The upward pitch is required so condensate will run back to the boiler for collection and disposal.

7. For vertical through the roof installations all gas vents extending above the roof by more than 2 1/2 feet must be securely guyed or braced (inside and outside wall) 2 clamps. Use a support ring to attach guys or braces to the vent pipe.

NOTE: ´ All venting must be mounted using spring isolators.

Vertical Vent Flashing and Installation

! 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.

Adhere to the following for vent  ashing installation:

1. The roof opening should be located and sized such that the vent is vertical and has the required air space clearance. The roof  ashing is positioned

with the lower portion of the base  ange over roo ng material. See Figure

17.

2. Nail through the upper portion and sides of the base  ange. Use nail with neoprene washers or cover the nail heads with a neoprene plastic. Finish roo ng around the  ashing, covering the sides and upper  ange with roo ng material.

Vertical Vent Termination

Adhere to the following for vertical vent termination:

1. The vent pipe must extend through the  ashing to a height above the roof as required in Figure 18. A storm collar is installed on the vent pipe over the opening between pipe and  ashing.

2. Adhesive material is used over the joint between the vent pipe and the storm collar. Figure 18. The vent termination is joined to the end of the vent pipe.

3. Termination height for the vent pipe must be such that no discharge opening is less than 2 feet horizontally from the roof surface, and the lowest discharge opening shall be no lower than the minimum height speci ed in Fig. 18. These minimum heights may be used provided the vent is not less than 8 feet from any vertical wall.

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

2-21

INSTALLATION PHW-IOM-2013-0214 SECTION 2

90° ELBOW

WIRES AND INSULATION

TO COMBUSTABLES,

AIR SPACE CLEARANCES

MAINTAIN MIN 9" / 22.86 CM

EXHAUST PIPE & FITTINGS

AL294C

AIR INLET

RISE TO RUN: 1/4" PER FOOT

Pulse Boiler

( SIDE VIEW )

1/4" TAPPING FOR WATER\

100 PSI MAXIMUM

INSTALL SUPPORT STRAPS AND SPRING HANGERS

AT 5FT / 152CM HORIZONTAL INTERVALS AND AT ELBOWS

( SPRING HANGERS ARE REQUIRED )

SUPPORT

ROOF

RECIRCULATION DURING DIFFERENT

POSSIBLE TO PREVENT FLUE GAS

SHOULD BE SEPERATED AS FAR AS

AIR INTAKE AND EXHAUST TERMINATION

NOTE:

( } 3 IN. / 7.62 CM )

4FT / 122 CM

FLASHING

ADJUSTABLE

SPACE CLEARANCE

IN REQUIRED AIR

INSULATION

DO NOT PLACE

PVC PIPE

FIRE STOP

METAL PLATE

PIPING

ABOVE AIR INTAKE

MIN 4FT / 122 CM

ADJUSTABLE

FLASHING

ADHESIVE SEAL

STORM COLLAR

OF AIR INTAKE OPENING

EXHAUST STACK IS DOWNWIND

SCREENED INLET

IF SNOW ACCUMULATION IS

APPLICABLE, OPENING TO BE

1 FT. / 30 CM ( MIN. ) ABOVE THIS

NORMALLY EXPECTED LEVEL.

( SUGGESTED TERMINATION CONFIGURATIONS )

TYPICAL ROOF PENETRATIONS

WIND CONDITIONS. NOTE: STACK SHOWN IS FOR REFERENCE PURPOSES ONLY. OTHER CONFIGURATIONS MAY BE ACCEPTABLE.

EXHAUST

USE OF ISOLATION CUBES OR SPRINGS IS REQUIRED

EXAMPLE OF SPRING HANGER

PROPER TRAP HEIGHT MUST BE ACHEIVED, AS SHOWN IN FIGURE 7

2-22

FIGURE 14 - TYPICAL CEILING AND ROOF PENETRATION DETAIL

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

FIGURE 15 - FIRE STOPPING REQUIRED FOR ALL CEILING/FLOOR

INSTALLATIONS

FIGURE 16 - FIRE STOPPING

FIGURE 17 - CORRECT ROOF FLASHING INSTALLATION

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

2-23

INSTALLATION PHW-IOM-2013-0214 SECTION 2

FIGURE 18 - ROOF PITCH

Horizontal Installation Wall Penetrations

Adhere to the following for horizontal wall penetrations:

1. Select the point of penetration where a minimum of 1/4” per foot upward pitch can be maintained.

2. When penetrating a non-combustible wall, the hole through the wall must be large enough to maintain the pitch of the vent and provide sealing. Use adhesive material to seal around the vent on both sides of the wall. When penetrating a combustible wall, a wall thimble must be used. See Figure 19 for installation instructions. Minimum wall thickness through which vent system may be installed is 3 1/4”. Maximum wall thickness through which vent system may be installed is 20 inches.

Wall Thimble Installation

Adhere to the following for wall thimble installation:

1. Insert a 9” diameter thimble through the wall from the

outside. Secure the outside  ange to the wall with nails or screws, and seal with adhesive material.

2. Install the inside  ange to the inside wall, secure with nails or screws, and seal with adhesive material.

3. Pass the vent pipe through the thimble from the outside and join to the rest of the vent system. Seal the pipe to the thimble  ange with adhesive material. See Figure 20.

4. Install two pipe retaining clamps around the intake as well as vent pipes on both ends of the wall thimble (on the inside and outside of the wall) through which

2-24

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

FIGURE 19 - HORIZONTAL INSTALLATION WALL PENETRATIONS

intake and vent pipes are passed, then tighten securely. They will prevent the intake and vent pipes from being pushed or pulled.

Horizontal Vent Termination

Adhere to the following for horizontal vent terminations:

1. Join the vent termination to the vent pipe outside the

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

wall. Use the same joining procedures for vent pipe and  ttings.

2. Ensure the termination of the vent system is at least 12” above the  nished grade, or at least 12” above normal snow accumulation level (for applicable geographical areas). Refer to Figure 19. The termination of the vent

system shall not be located in tra c areas such as walkways, adjacent buildings, openable windows and building openings unless the venting system is at least

2-25

INSTALLATION PHW-IOM-2013-0214 SECTION 2

! WARNING

Do not attempt to start the boiler before

 lling and purging the boiler system. A dry  re may cause injury, may seriously damage the boiler, may result in property damage, and will void the warranty.

FIGURE 20 - WALL THIMBLE INSTALLATION

7 feet above  nished grade, (National Fuel Gas Code, ANSI Z223.1).

3. The vent termination must be at least 4 feet (1.22m) horizontally from, and in no case above or below, unless a 4-foot (1.22m) horizontal distance is maintained from electric meters, gas meters, regulators, and relief equipment.

4. The air supply inlet and exhaust outlet must be separated from 4 ft. minimum to 10 ft. maximum on the same wall. The exhaust outlet must be installed 4 ft. minimum above and downwind from air supply inlet to prevent exhaust recirculation.

5. Under certain wind conditions, some building materials may be a ected by  ue products expelled in close proximity to unprotected surfaces. Sealing or shielding of the exposed surfaces with a corrosion resistant material (such as aluminum sheet) may be required to prevent staining or deterioration. Do not locate the vent termination too close to shrubbery as  ue products may stunt their growth or kill them.

After Installation/Prior to Start-Up

2-26

Completely  ll and purge the heating system using the following sample procedure:

NOTE: ´ The following purge procedure is applicable to the piping

con guration as shown in Figure 21.

1. Close combination shuto /purge valve in supply, all drain cocks, the

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

RETURN FROM SPACE HEATING SYSTEM

DRAIN

9

13

10

12

11

10

9

7

14

*

*ALTERNATE LOCATION

COLD WATER SUPPLY

BOILER

1

2

3

4

5

7

8

6

HIGH POINT

AIR VENT

VENT

(TYPICAL)

Legend:

1. Temperature/ Pressure Indicator

2. Hot Water Outlet Stop Valve

3. Safety Valve

4. Combo Shuto / Purge Valve

5. Auto Air Vent

6. Air Scoop

7. Circulator

8. Heat User

9. Zone Valve

10. Stop Valve

11. Check Valve

12. Pressure Reducing Valve

13. Diaphragm Expansion Tank

14. Drain Valve

FIGURE 21 - PURGE EXAMPLE

shuto valve for the pressure reducing ( ll) valve, and all manual air vents.

2. Open all other system shuto valves one of the zone valves, the vent on the combination shuto / purge valve, and the shuto valve to the pressure reducing ( ll) valve.

3. Water will now begin to  ll the system. Air will escape through the vent on the combination shuto / purge valve. Continue  lling until a constant stream of water (no bubbling) is discharged from the vent.

4. Close the zone valve on the purged loop, and open the zone valve on the next loop to be purged. When all air has escaped and only water is discharged, close the zone valve. When all zones have been purged. (one at a time), close the vent on the combination shuto / purge valve.

5. At this point, the system has been initially  lled. However, air pockets may still remain at high points in the system and in heating loops above the level of the combination shut/o purge valve. It is quite possible, depending on the particular system that all

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

6. Open the combination shuto / purge valve (keep the

7. Again, open manual air vents at high points of heating

8. Check temperature/pressure indicator reading, which

9. Visually inspect all pipe joints and equipment

piping above the combination shuto /purge valve still contains air. If manual vents are installed on the system high points, these should be opened to vent these locations. When only water is discharged from all vents, the initial purging is complete.

vent closed). With the gas shuto valve closed, turn on power to the boiler and operate the circulator. Circulate the system water for approximately 30 minutes to move all air to the automatic air separation point.

loop until a constant stream of water is discharged from the vent. Close the vent and make sure it’s watertight. Repeat procedure for all high points and for every zone.

should equal the pressure reducing ( ll) valve set pressure. No more water should be entering the system. Close the shuto valve on the cold water  ll line.

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

2-27

INSTALLATION PHW-IOM-2013-0214 SECTION 2

system may be considered water tight.

4 CAUTION

Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water damage can occur.

10. When purging is completed, make sure the following are open—

combination shut-o /purge valve, shuto valve to pressure reducing ( ll valve), shuto valve in cold water  ll line, and shuto valve in return line.

11. Make sure the following are closed--all drain cocks, the vent on the combination shuto -purge valve, and all manual vents. Reset zone valves to normal mode of operation and turn o power to boiler.

12. Open gas shuto valve, allowing gas to  ow to boiler.

Installation Checkpoints

§ Do not turn on the boiler unless it is  lled with water as shown by

indicating light on panel box.

§ Check that the front door of the air decoupler box is closed. Door must be

closed before starting the boiler. Do not open during operation.

§ Set the temperature control to the desired setting. Refer to Operation

section of this manual for setting the setpoint.

§ Open the manual shut o gas valve.

§ Close the circuit breaker or the fuse disconnect.

§ Turn the on-o switch to “ON.”

Testing Ignition Safety Shut Oﬀ

Perform the following:

1. Open gas shut o valve, allowing gas to  ow to boiler.

2. Close gas shut o valve.

3. Reset low gas pressure switch.

4. Turn on the boiler. The boiler will run through its purge and trial for ignition cycle. After 6 seconds of ignition trial, the boiler will recycle. Switch the boiler o .

5. Open the gas shut o valve.

2-28

6. Restart the boiler.

Measure Gas Flow Rate

Perform the following:

1. Turn o the boiler and close the manual gas shuto valve. Remove manifold (downstream) pressure test plug from the 90 degree elbow.

SECTION 2 PHW-IOM-2013-0214 INSTALLATION

Rating the Boiler

After the boiler has been operating for about 15 minutes, check gas input rate to be sure boiler is operating at design capacity.

To Check for High Gas Pressure

Adhere to the following:

1. The boiler and its individual shut-o valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa).

2. Turn o boiler and turn o gas supply to manual gas shuto valve. Remove the pressure test plug on manual shuto gas valve. Replace with a 1/4” NPT to

1/4” compression (or  ange) adaptor and a short piece

FIGURE 22 - REMOVING CAP FROM REGULATOR

of tubing. Connect a piece of rubber hose from tubing to a manometer.

2. Replace the plug with a 1/4 N.P.T. to 1/4” compression

(or  are) adaptor and a short piece of tubing. Connect a piece of rubber hose from the tubing to a manometer.

Open the gas shuto valve (gas cock) and turn on boiler.

3. Inlet Pressure for Natural gas  red units should be a minimum of 7” WC while running. Inlet pressure for Propane should be a minimum of 11”WC while running. See factory test  re sheet for manifold operating pressures.

¡ To Correct Input – Adjust Gas Pressure Regulator

Perform the following:

1. Turn boiler o and remove cap from regulator. (Figure

22).

2. Turn adjusting screw clockwise to increase gas  ow. Turn adjusting screw counter-clockwise to decrease gas  ow.

3. Always replace cap before turning on boiler.

4. Regulator vent must terminate outdoors.

5. A  ow restricting bleed valve shall not be used on the regulator vent.

3. Open gas supply to manual gas shuto valve and turn on boiler. After combustion starts, manometer should read 7” WC (178mm) minimum for natural gas and 11” WC (25mm) minimum for propane.

4. If reading exceeds 14” WC. (178mm) install regulator upstream of gas valve to reduce pressure.

For High Gas Pressure Installations Using Fisher Regulators

In high gas pressure areas, it is good practice to step the pressure down as described below:

1. Locate the stepdown regulator as far away from the Pulse boiler as possible. At a minimum, it should be 10 feet from boiler.

2. When stepping down from more than 5 psig to 14” WC, the stepdown should be done in two steps:

§ Reduce the pressure to 5 psig

§ Reduce the pressure from 5 psig to 14” WC

3. The preferred stepdown regulator for this application is manufactured by Fisher. Consult your Authorized Fulton Representative for selection. This recommendation is made to avoid regulator chatter. It is also recommended to avoid high lockup pressures which can cause light o

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

2-29

INSTALLATION PHW-IOM-2013-0214 SECTION 2

reliability problems. Regulators, other than speci ed, may be acceptable, but it has been our experience that Fisher regulators operate the most satisfactorily.

4. Recommendations for installing step down regulators:

§ There must be a minimum of 10 pipe diameters of

straight pipe before the inlet and after the outlet of the regulator.

§ Vent pipe must not be reduced to a smaller size than

the opening size of the regulator vent. Use the next size pipe for every ten inches of pipe.

§ Install a union close to the outlet of the regulator for

ease of removal and maintenance.

§ Vent to a safe area.

Before Leaving the Installation

1. Check all controls to insure they are operating properly. Cycle boiler several times by raising and lowering operating temperature on the temperature controller.

2. Make sure installation complies with all applicable codes.

2-30

OPERATION

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE WARRANTY & PARTS

3

4 5

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

3-1

OPERATION PHW-IOM-2013-0214 SECTION 3

! 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. Failure to follow instructions may result

in a  re or explosion, causing property damage, personal injury, or loss of life.

This boiler is equipped with an ignition device, which automatically lights the burner. Do not try to light the burner by hand.

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

Use only your hand to turn the valve handle. Never use tools. If the knob will not turn by hand, don’t try to repair it. Call a quali ed service technician. FORCE OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION.

WHAT TO DO 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 neighbor’s phone. Follow the gas supplier’s instructions. • If you cannot reach your gas supplier, call the  re department. -A quali ed installer, service agency or the gas supplier, must perform installation and service.

Before Start Up

Fulton Pulse combustion boilers do not have a pilot. They are equipped with an ignition device which automatically lights the boiler. Do not try to light the boiler by hand.

Before start up, perform the following safety checks:

§ 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 light any appliance.

» Do not touch any electric switch.

» Do not use any phone in your building. Immediately call your

gas supplier from a neighbor’s phone, and then follow your gas supplier’s instructions. If you cannot reach your gas supplier, call

the  re department.

§ Ensure no part of this boiler has been under water. Immediately call a

quali ed service technician to inspect the boiler and to replace any part of the control system and/or gas control(s) which has been under water.

§ Ensure you have read and followed all previous safety information.

§ Turn o all electric power to the boiler.

§ Turn gas cock handle clockwise to “OFF”. Figure 23. (This gas cock handle

is also the emergency shut-o device.) Use only your hand to turn the gas cock handle. Never use tools. If the handle will not turn by hand, don’t try

to repair it. Call a quali ed service technician. FORCED OR ATTEMPTED REPAIR MAY RESULT IN A FIRE OR EXPLOSION.

Do not use this boiler if any part has been under water. Immediately call a quali ed service technician to inspect the boiler and to replace any impacted part of the control system.

3-2

FIGURE 23 - GAS COCK HANDLE IN OFF POSITION

Start-Up

Perform the following to start boiler:

1. Open the main gas cock handle counter clockwise 1/4 turn to “ON” position (Figure 24).

2. Turn on all electric power to the boiler.

SECTION 3 PHW-IOM-2013-0214 OPERATION

3. Set temperature control to desired setpoint.

4. Turn operating switch on boiler to “ON” position. The boiler is energized and 35 second prepurge begins. After 35 seconds the spark ignitor and gas valve (2 seconds later) are energized. If combustion is not sensed within 4 seconds, gas and spark are de-energized. The control will recycle to prepurge, only if the allowed number of retry attempts is not exceeded.

5. If the gas valve opens but the boiler does not start, check the spark plug to be sure it is working properly.

6. The plug may be bad or the plug wire may be loose. Check gap of plug. It should be .050” to .060”. When replacing the spark plug be sure to use Never Seize on threads of plug.

7. When the unit  res and pressure is sensed in air valve housing and the  ame rod senses  ame, the unit will continue to operate until main power

is shut o to the controller either through the temperature switch or main power switch. Once the pressure is sensed in the air valve housing (proof of

 ame) and the  ame rod senses  ame, the assist fan and spark will turn o .

8. Do not change  ame pressure switch settings.

9. Should overheating occur, or the gas supply fails to shut o , shut o the gas supply at a location external to the boiler.

! WARNING

Do not attempt to start the boiler for

any testing 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.

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

Never attempt to operate a boiler that has failed to pass all the safety checks.

Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water damage could occur.

4 CAUTION

FIGURE 24  GAS COCK HANDLE IN ON POSITION

¡ Linkage Adjustment for Pulse Modulated Boilers

The following covers the adjustment of the linkage arms and rods between the modulation (mod) motor and gas butter y valve, and also between the mod motor and exhaust butter y valve. Prior to start-up, ensure both the gas and exhaust butter y valves are in the closed position with the boiler o .

} SETTING HIGH FIRE

1. When the boiler is energized, the mod motor will be driven to High Fire driving the gas and exhaust butter y valves to the open position. At High Fire the slot in the shaft of the mod motor should be horizontal in orientation. At this point it is important to note that the mod motor and gas butter y valve linkage arms are as close to parallel as possible. Also note that the mod motor and exhaust butter y valve linkage arms should be parallel. Location of the lock nuts on the linkage rods is not important.

Do not use this equipment if any part has been under water (or subjected to heavy rains/water if the equipment does not have NEMA 4 wiring, controls and instrumentation). Immediately

call a quali ed service technician to inspect the equipment and to replace any part of the control system and/or gas control(s) which have been under water.

Commissioning/Start up by a nonFulton authorized person will void the product warranty.

Please read these instructions and post in an appropriate place near the equipment. Maintain in good legible condition.

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

3-3

OPERATION PHW-IOM-2013-0214 SECTION 3

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

4 CAUTION

After checking controls by manual adjustment, make sure they are always reset to their proper settings.

When making changes to the controls

pro le, a combustion analyzer is required.

Check daily that the equipment area is free and clear of any combustible

materials, including  ammable vapors and liquids.

Water chemistry in the boiler must be kept within required limits. Failure to do so may cause premature pressure vessel failure and will void the warranty.

} LINKAGE RELATIONSHIPS

The location of the linkage rods and the speed at which the butter y gas valve and butter y exhaust valve opens or closes will determine whether the unit operates smoothly or not.

} GAS BUTTERFLY VALVE SIDE

The longer the radius on the mod motor pivot arm, the quicker the gas butter y

valve shuts o . Conversely, the shorter the radius the slower the gas butter y valve shuts o . The longer the radius on the gas valve pivot arm, the slower the gas butter y valve shuts o . Conversely, the shorter the radius the quicker the gas butter y valve shuts o .

} EXHAUST BUTTERFLY VALVE SIDE

1. The longer the radius on the mod motor pivot arm, the quicker the exhaust butter y valve shuts o . Conversely, the shorter the radius the slower the exhaust butter y valve shuts o .

2. The longer the radius on the exhaust valve pivot arm, the slower the exhaust butter y valve shuts o . Conversely, the shorter the radius the quicker the exhaust butter y valve shuts o .

3. At High Fire the linkage arms should NOT begin or  nish travel in the vertical position. If this occurs there is a possibility that the gears will bind and cause damage to the mod motor.

4. The gas pressure regulator is the only means for adjusting High Fire input to the factory test  re values. After the boiler is operated at High Fire to the desired settings, proceed to operate at Low Fire.

5. Before the boiler  res at high  re:

§ Access Status screen on SOLA Control and press Operation.

§ Press yellow box next to Firing Rate.

§ Change Automatic to Manual in Run, and key in 100%. Press OK. Refer to

Figure 25.

FIGURE 25  EDIT THE FIRING RATE

3-4

SECTION 3 PHW-IOM-2013-0214 OPERATION

6. Check combustion at high  re. Make adjustments to air  apper, and incoming gas. Air  apper adjustments are to be made at high  re only.

NOTE: ´ At high  re, the gas and exhaust butter y valve will be

full open in the horizontal position.

} LOW FIRE SETTINGS

1. Manually adjust the temperature controller on the front of the boiler to read 50% input. At 50% check to see if the unit is within test  re values. Proceed to step the boiler down to 40%, 30%, 20% 10% and 0% each time checking to see if the unit is within test  re values. 0% represents low  re and 100% represents high  re.

2. If you are unable to reach 0%, you will need to make adjustments on the gas valve to either increase or decrease fuel input. The exhaust butter y valve may also need adjustment. Start by adjusting one valve at a time.

3. The gas butter y valve should be used to adjust Low Fire input. The exhaust butter y valve should be adjusted to set proper combustion. Closing the exhaust butter y valve will also decrease input slightly.

6. Set the 4-20 mA source to 4 mA to drive the motor to the closed position.

7. Turn the start potentiometer slowly counterclockwise

until the motor begins to open. This is de ned as the start or zero position.

8. Set the 4-20 mA source to 20 mA to drive the motor to the fully open position. The motor will open.

9. Turn the span potentiometer clockwise until the motor

starts to close. The di erence between the fully open span position current and the zero position current is

de ned as the operating span.

10. Recheck the start and readjust the span potentiometer if necessary. Turn the start potentiometer clockwise to increase the zero position.

11. Recheck the span and readjust the span potentiometer if necessary. Turn it clockwise to increase the full span position.

12. Power down 4-20 mA source and boiler.

13. Remove 4-20 mA source, and rewire the mod motor.

14. Power boiler up, and turn switch to On.

4. At Low Fire the linkage arms should NOT begin or  nish travel in the vertical position. If this occurs there is a possibility that the gears will bind and cause damage to the mod motor.

} PROCEDURE TO ZERO AND SPAN THE MODULATION MOTOR

The following steps are performed on each modulation (mod) motor at the factory. It may be necessary to do in the  eld in the event the mod motor requires replacement or the mod motor linkage is moving up or down the range when there is no change in the operating or setpoint temperature

di erence.

1. Turn switch to O position and power down the boiler.

2. Disconnect (-) and (+) from the mod motor. Tape or wire bug the loose electrical wires.

3. Using a 4-20 mA source, connect (+) lead to (+), and (-) lead to (-) on the mod motor.

4. Adjust the start potentiometer fully clockwise (maximum zero) and the span potentiometer fully counterclockwise (minimum span).

¡ If the Boiler Doesn’t Start

Proceed as follows:

1. Adjust blocked air intake switch (BIS)

2. Screw the switch fully in. Do not over tighten the screw.

3. With the boiler running in manual and 100% high  re,

back the switch out until the boiler switches o .

4. Turn the BIS in one full turn.

5. Re-start the boiler.

NOTE: ´ Do not change the Flame Pressure Switch settings.

6. Check that the temperature control is set higher than water temperature in the boiler. Check for tripped circuit breaker or blown fuse.

7. Check for possible restrictions (foreign objects, snow, rags, leaves, etc.) in either the air supply inlet or the exhaust outlet on the outside of the building. Check for proper water level in the boiler (low water cuto ).

5. Reapply power to the boiler.

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

8. If the boiler still does not operate, follow these

3-5

OPERATION PHW-IOM-2013-0214 SECTION 3

instructions to shut o the gas and call your service technician and/or gas supplier:

9. Turn o all electric power to the boiler if service is required.

10. Turn gas cock handle clockwise to “OFF”.

Sequence of Operation for Modulated Pulse Hydronic Boilers

The following is a typical sequence of operation:

1. When the boiler receives a call for heat, the prepurge cycle is initiated.

2. The mod motor is driven to high  re.

3. After the high  re switch in the mod motor is closed, the prepurge count begins.

4. Following prepurge, the spark generator energizes and the gas valves open.

General Operation of the Boiler

Excessive cycling will reduce the useful life of any piece of mechanical equipment. Pulse boilers should be operated and controlled so the boiler cycles less than 12,000 times per year. Pulse boilers should be operated and controlled so that the temperature di erential across the boiler does not exceed 100 F (38 C).

Programming Instructions for the SOLA Control

The SOLA control has been factory-programmed and requires no alteration of program presets. Only factory trained personnel should attempt to alter password protected presets. Primary screens are shown on the following pages.

5. Upon proof of  ame, the fan and spark are turned o .

6. At this point, the modulation temperature controller

controls the mod motor and  ring rate of the boiler.

7. When the boiler outlet temperature reaches set point,

the boiler is turned o and prepurge begins.

8. The boiler control then monitors the outlet temperature and waits for the next call for heat.

3-6

SECTION 3 PHW-IOM-2013-0214 OPERATION

PRIMARY SCREENS ON THE SOLA CONTROL

SOLA Control Screen Example Screen Shot

Home Screen

Touch the SOLA to access the Status Summary Screen.

Status Summary Screen

From this screen the control can be con gured. It also provides a snap shot status of the boiler.

Central Heat Operation Screen

From the Status Summary Screen press the Operation button. From this screen the setpoint can be changed or the unit can be placed into manual for maintenance or combustion checks. Pressing the yellow highlighted box next to Firing Rate will provide access to the Firing Rate Screen.

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

3-7

OPERATION PHW-IOM-2013-0214 SECTION 3

SOLA Control Screen Example Screen Shot

Firing Rate Screen

In this example screen, the boiler is in automatic. By pressing the circle next to Manual in Run, the unit will go to manual. Pressing Clear will remove the current  ring rate percentage and permit you to enter a new percentage. Press OK. The boiler will go to that  ring rate.

Setpoint Screen

Access this screen by pressing the yellow highlighted box next to Normal from the Central Heat Operation Screen. From here you can press clear, enter the required setpoint, then press OK.

Con guration Menu Screen

Access this menu screen by pressing Con gure in the

Status Summary Screen.

Central Heat Con guration – Setpoint Screen

From the list of Parameters, press the CH – Central Heat Con guration. You will now be in the Central Heat Con guration Screen, Central Heat page. Press the upper right black arrow until you get to the Setpoint Screen. From this screen you can see this is another location where the Setpoint can be changed

but this is the only location that the Hysteresis (on/o around setpoint) can be changed. To change any of these settings the sola password must be entered.

3-8

SECTION 3 PHW-IOM-2013-0214 OPERATION

SOLA Control Screen Example Screen Shot

Central Heat Con guration – Modulation Screen

By pressing the black arrow on the top of the page you will be able to move from the previous Setpoint screen to the Modulation Screen, In this screen you will have access to the PID (Proportional, Integral and Derivative) of the control. The sola password is required to change these parameters.

Statistics Screen

From this screen you can view cycles and hours of the boiler. It is accessed from the Con guration Menu Screen. Please note that they can be cleared by pressing Clear All. This is not recommended.

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

3-9

OPERATION PHW-IOM-2013-0214 SECTION 3

! 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.

Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.

¡ Changing/Testing SOLA High Limit Setpoint

Perform the following to change the High Limit Setpoint and verify the change:

1. From the Status Summary Screen press Con gure then scroll down to and press High Limits, this screen will be used to set and/or test the Outlet High Limit Setpoint. See Figure 26.

2. Enter the SOLA password by pressing the padlock icon and typing sola.

3. By touching the Setpoint next to Outlet High Limit Setpoint, you can adjust the temperature up and down for the Setpoint you desire or lower it for testing purposes. A change will require Veri cation (see below).

FIGURE 26 - HIGH LIMIT SETPOINT

¡ Verifying Changes to High Limit Setpoint

4. Arrow back to the con guration menu and press Verify in the lower right hand corner. See Figure 27.

FIGURE 27 - HIGH LIMIT SETPOINT

5. Press the Padlock in the upper right hand corner and enter the password sola (if not already unlocked) then press Begin down in the lower right hand corner. See Figure 28.

3-10

6. The parameters that you changed will appear, verify the change you made is correct. Then press Yes. See Figure 29.

7. If there are no more changes the control will ask you for a reset. This can

SECTION 3 PHW-IOM-2013-0214 OPERATION

be done by pressing the reset button on the front of the Sola control (the base) for 1 to 2 seconds. See Figure 30.

FIGURE 28 - VERIFICATION

! 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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

FIGURE 29 - VERIFICATION

FIGURE 30 - VERIFICATION

¡ Accessing Lockout History and Clearing Lockouts

1. From the Status Summary screen resetting the lockout or viewing the lockout history can be accessed by pressing where Figure 31 is showing a Lockout. If there is no lockout, that same bar will display History.

2. If the control is in lockout another sub screen will be displayed and you will have the option for Ok, Lockouts, Alerts and Silence. Pressing Lockouts will display the screen shown in Figure 32. This will provide the time and date

stamp of the last  fteen lockouts. By pressing the speci c lockout more

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

3-11

OPERATION PHW-IOM-2013-0214 SECTION 3

information on the lockout can be displayed. This expanded annunication

4 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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

will assist in troubleshooting. Pressing Clear Lockout will clear the current lockout. See Figure 32.

FIGURE 31 - CONTROL LOCKOUT

3-12

FIGURE 32 - CONTROL LOCKOUT HISTORY SCREEN

¡ Procedure for Remote Firing Rate Using a 4-20mA Signal (Single

Boiler)

1. From the Status Summary Screen press Con g, arrow down to and press Sensor Con guration. Choose S2 (J8-6) Sensor, this will require the sola password. Choose 4-20mA. See Figure 33. This will also require a veri cation. See High Water Temperature Limit section for veri cation steps.

2. Back out to the Con g screen and go to CH Central Heat Con guration. Arrow over to Modulation. See Figure 34.

3. Press Modulation Rate Source and pick S2 (J8-6) 4-20ma with sensor on/

o . With an external 4-20mA, 4mA will equal Low Fire, and 20mA will equal High Fire.

4. Choosing sensor on/o will require setting the internal setpoint higher

SECTION 3 PHW-IOM-2013-0214 OPERATION

! CAUTION

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

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

FIGURE 33 - SENSOR CONFIGURATION SCREEN

FIGURE 34 - MODULATION

than what may be required. The boiler will shut o at this setpoint if remote contacts are not opened.

NOTE: ´ Selecting Burner On/O will require remote on/o (stop/start) contacts.

¡ Procedure for Remote Setpoint Using a 4-20mA Signal (Single

Boiler)

1. From the Status Summary Screen press Con g, arrow down to and press Sensor Con guration. Choose S2 (J8-6) Sensor, this will require the sola password. Choose 4-20mA. See Figure 33. This will also require a veri cation. See High Water Temperature Limit section for veri cation steps.

2. In Central Heat Con guration in the Modulation screen, the Modulation Rate Source must be Local. See Figure 34.

3. In Central Heat Con guration in the Setpoint screen, change Setpoint source to S2 (J8-6) 4-20mA; and change the 4mA Water Temperature and 20mA Water Temperature to the required setting. See Figure 35.

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

3-13

OPERATION PHW-IOM-2013-0214 SECTION 3

! 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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

FIGURE 35  CHANGING SETPOINT IN CENTRAL HEAT CONFIGURATION SCREEN

¡ Procedure for Lead/Lag with Outdoor Reset with Multiple Boilers

Items required:

§ One Supply Header Sensor Kit. Kit to include Thermowell, 2x4” Handy

Box and clip to attach thermowell to handy box

§ One Outdoor Sensor and Interface Module Kit. Kit to include outdoor

sensor, NEMA 4 box, squeeze connector for sensor and interface Module. Interface Module must be mounted on the other side of the wall (inside the building) from outdoor sensor this will ensure it is as close to the sensor as possible.

4. Speci c parameter changes that are required will prompt you for a password, the password is sola. Also some of the changes will require a Veri cation of your change. The Veri cation process can be accomplished after all the changes are made.

NOTE: ´ See Figure 51 for diagram of boilers in a lead/lag outdoor reset

application.

Proceed as follows:

1. From the Status Summary page press Con gure to access the

Con guration Menu. See Figure 36.

3-14

2. For the Master Boiler in the Con guration Menu select Lead Lag Master Con guration. Press Master enable and select Enable. Then select Advanced Settings in the lower right of this screen. See Figure 37.

3. Master Boiler - In the Advanced Settings of Lead Lag Master Con guration arrow over to Outdoor Reset. Press Enable and select Enabled. Also in this screen there are 3 of your 4 points that can be chosen for your outdoor reset curve. Maximum outdoor temperature relates to low water

SECTION 3 PHW-IOM-2013-0214 OPERATION

temperature. Minimum outdoor temperature relates to Central Heat Setpoint. See Figure 38. Minimum boiler water temperature should be the lowest temperature at which you want the boiler to function.

4. Master Boiler – While still in the Advanced Settings Screen, arrow over to Central Heat and Select your Setpoint. This is what your Minimum outdoor temp will relate to on the curve. Once all 4 numbers are entered

FIGURE 36 - ACCESSING THE CONFIGURATION MENU

! WARNING

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

Operating this equipment beyond its design limits can damage the equipment and can be dangerous. Do not operate the equipment outside of its limits. Do not try to upgrade the equipment performance

through unapproved modi cations. Unapproved modi cations may cause injury, equipment damage, and will void the warranty.

FIGURE 37 - ADVANCED SETTINGS

FIGURE 38 - OUTDOOR RESET

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

3-15

OPERATION PHW-IOM-2013-0214 SECTION 3

! WARNING

Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections

of this manual and are quali ed to operate/maintain the equipment.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

you can look at your curve in the previous screen, press Show Line. See Figure 39.

5. Master Boiler – While still in the Advanced Settings Screen arrow over to Warm Weather Shutdown. If required, Select Enable and press Shutdown after demand ends. Then select the Setpoint (outside air temperature) at which you want the system to shut down. See Figure 40.

FIGURE 39 - SELECTING CENTRAL HEAT SETPOINT

3-16

FIGURE 40 - WARM WEATHER SHUTDOWN

6. For the Master Boiler, back out to the Con guration Menu, select Lead Lag Slave Con guration and select Slave Enable - Enable slave for built-in Lead Lag Master. See Figure 41.

FIGURE 41 - LEAD LAG SLAVE CONFIGURATION

SECTION 3 PHW-IOM-2013-0214 OPERATION

7. For the Slave Boiler(s), go to the Con guration Menu, select Lead Lag Slave Con guration and select Slave Enable - Enable slave for built-in Lead Lag Master. See Figure 41.

8. Master Boiler - Sensor Selection: In the Con guration Menu go to Sensor Con guration. Press sensor Outdoor temperature source, select Enviracom Outdoor Sensor. Also change S5 (J8-11) sensor to 10K NTC single nonsafety, this is your header sensor. See Figure 42.

FIGURE 42 - SENSOR CONFIGURATION

! 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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

9. Master and Slave Boiler - Back out to the Con guration Menu and select System Identi cation and Access. See Figure 43. This is where the address of each boiler will be selected at MB1 Modbus Address. The boilers will be daisy chained to each other through MB1 on the base of the

FIGURE 43 - SYSTEM IDENTIFICATION AND ACCESS

control. The master boiler will be address 1 as shown in Figure 42. The next “slave” boilers will be 2,3,4… depending on the amount of boilers. Each boiler will have its own address.

10. Perform veri cation of changes. See Figure 44.

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

3-17

OPERATION PHW-IOM-2013-0214 SECTION 3

! 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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

FIGURE 44 - VERIFICATION OF CHANGES

¡ Single Boiler Outdoor Reset Programming

1. From the status summary screen press Con gure. Press CH- Central Heat Con guration. See Figure 45.

FIGURE 45 - ACCESSING CENTRAL HEAT CONFIGURATION

2. Arrow over to Setpoint and verify that the Setpoint is the desired temperature in relation to the Minimum outdoor temperature (see Figures 46 and 47).

3-18

3. Arrow over to the Central Heat page (Figure 47). In this screen 3 of your 4 points that can be chosen for your outdoor reset curve. Maximum outdoor temperature which relates to your Low water temperature and your Minimum outdoor temperature relates to your Central Heat Setpoint in the setpoint screen. Your Minimum boiler water temperature should be the lowest temperature at which you want the boiler to operate.

SECTION 3 PHW-IOM-2013-0214 OPERATION

! 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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

FIGURE 46 - VERIFYING SETPOINT

FIGURE 47 - OUTDOOR RESET CONFIGURATION

4. By pressing Show Line in the Outdoor Reset Con guration screen you can see outdoor temperatures in relation to your water temperatures in a linear format. See Figure 48.

FIGURE 48 - CENTRAL HEAT OUTDOOR RESET

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

3-19

OPERATION PHW-IOM-2013-0214 SECTION 3

! 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.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

5. Back out to the Con gure Screen and press Sensor Con guration. The “sola” password will need to be entered. Press the Outdoor temperature source and choose EnviraCOM outdoor source. See Figure 49.

NOTE: ´ The 1ea (KIT) 2-40-001072, outdoor sensor and Interface Module is

required, wired to the Sola base ECOM terminals 1,2, and 3.

FIGURE 49 - SENSOR CONFIGURATION

6. Back out to the Con gure menu and press Verify and complete the veri cation process. See Figure 50.

FIGURE 50 - VERIFICATION

3-20

SECTION 3 PHW-IOM-2013-0214 OPERATION

Third Party SOLA Control

The Pulse SOLA Control provides the capability of control and/or monitoring by a third party. The standard SOLA control protocol is Modbus.

¡ Lead/Lag Outdoor Reset Conﬁ guration Using

Communication Port 2

If the boilers are set up to be lead/lag with outdoor reset all the communication connections on the J3 plug of the SOLA control will be used. Third party control can be wired to the SOLA display on communication port 2. If requested at the time of the boiler order, the communication port will be activated at the factory. Only the baud rate may have to

be changed in the  eld. When the boilers are con gured for lead/lag outdoor reset, only the master boiler needs to have the third party connection. Multiple points of the lag boilers can be viewed from the Master boiler. Refer to Figure 52. Figure 52 shows wiring connection to the display’s communication port 2. Use the website link and/or QR code in this section of the manual to access additional information on setting up the communication port 2.

¡ Gateways

Fulton o ers (as an option) a Modbus to Bacnet gateway. The gateway will come pre-programmed and wired in one, or if desired, all of the boilers. If the boilers are daisy chained together through J3, MB1 one gateway can be used on the master boiler which will be wired to communication port 2 of the master display. Use the website link and/or QR code in this section of the manual to access additional information on pre-programmed gateway information (read and write addresses) and setup instructions.

NOTE: ´ Although there are many points that are available

through Modbus, special care must be taken when writing

to them. There are speci c write addresses that will utilize an internal Sola control EEPROM. The Sola control requires a write command only when the user intends to change a value. Continuously writing to the control will  ll the SOLA’s EEPROM memory, causing various non-safety parameters to change. All of the information out of the control is in Celsius; this may have to be converted to Fahrenheit if desired. Firing rate also requires a conversion. Please refer to the website link and QR code for more information.

¡ Stand Alone Boilers Controlled by a Third Party

Control

If the boilers are not set up to be lead/lag outdoor reset, a third party control can land connection to J3, MB1 on the SOLA control. If this is known at the time the boiler order is entered, the control will be set up for this type of control. Please refer to Figure 52 for J3, MB1 connections. The communication wires can be daisy chained to each boiler. Use the website link and/or QR code in this section of the manual to access additional information on setting up the MB1.

} WEB ADDRESS FOR FURTHER INFORMATION

http://goo.gl/O8I7U

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

3-21

OPERATION PHW-IOM-2013-0214 SECTION 3

J3 ECOM 1,2,3

For Outdoo r

Sensor Inte rface

Module

J8 (S5) terminal s

11 & 12 For

Header Se nsor

POWER

FLAME

ALARM

RESET

2-40-000907

BOILER

Master

A B C

J3 (MB1) A,B,C

For daisy chain of

boilers

Com 1 and 24

VAC of the

display will be

pre-wired at the

factory

S7999D Display

POWER

FLAME

ALARM

RESET

2-40-000907

BOILER

Lag

A B C

J3 (MB1) A,B,C

For daisy chain of

boilers

Com 1 and 24

VAC of the

display will be

pre-wired at the

factory

S7999D Display

POWER

FLAME

ALARM

RESET

2-40-000907

BOILER

Lag

A B C

J3 (MB1) A,B,C

For daisy chain of

boilers

Com 1 and 24

VAC of the

display will be

pre-wired at the

factory

S7999D

Display

COM 1 1 COM 2 24 VAC

A B CA B C COM POWER

COM 1 1 COM 2 24 VAC

A B CA B C COM POWER

COM 1 1 COM 2 24 VAC

A B CA B C COM POWER

Clamp

Filter

TE

Water Header

Honeywell Header

Sensor and Well

Outdoor Sensor Interface Module

1 2 3 OT OT

Communication wire, Modbus for BMS

RS-4 85 message forma t:

1 start bi t 8 data bits

No parit y bit

1 stop bit

Note: If boi lers are daisy chan ied together onl y one BMS

connect ion is required to th e master.

Communica tion wire

Outside

Wall

Outdoor Sensor

Interface Module,

mounted inside as

close to outdoor

sensor as possible

Honeywell Sensor and Well

Outside Air Sensor

2 wire, landed on

“OT” of interface

Module, Field Wiring

Outdoor Sensor

1

3 Wires Connected to Master Boiler (J3 ECOM terminals 1,2 and 3), Field Wiring

2

Field Wiring

3

Clamp Filter all connections to D display

4

4 3

1

2

Header Sensor

3-22

FIGURE 51 - LEAD/LAG OF HYDRONIC BOILERS USING THE SOLA CONTROL (MAXIMUM OF 8 BOILERS)

SECTION 3 PHW-IOM-2013-0214 OPERATION

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

FIGURE 52 - EXAMPLE/TYPICAL ELECTRICAL DIAGRAM

3-23

OPERATION PHW-IOM-2013-0214 SECTION 3

3-24

MAINTENANCE

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE

WARRANTY & PARTS

3

4

5

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

4-1

MAINTENANCE PHW-IOM-2013-0214 SECTION 4

! 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.

Prior to any maintenance concerning electrical components of this equipment, ensure electrical supply to the equipment is disconnected. Label all wires prior to disconnection; wiring errors may cause improper and hazardous operation.

Follow all proper lockout/tagout procedures for service.

Before beginning any maintenance, ensure area is free of any combustible materials and other dangers.

General

Your Pulse boiler has been designed to provide years of trouble free

performance. To ensure continued safety and e ciency of the boiler, please follow the maintenance and inspection directions outlined in this section of the manual.

Daily, Weekly and Monthly Maintenance and Inspection (Fulton considers the following to be good practice for any boiler, and is applicable to the full line of Pulse boilers).

1. Before each heating season, check the following:

§ Air intake and exhaust vent outlet for blockage or restrictions

§ Exhaust piping for leaks

§ Heating system or boiler piping for leaks

§ Air intake and exhaust vent piping for sagging

2. Follow the purge procedure outlined in this manual.

3. Follow the Start-Up Procedure outlined in this manual.

4. With the boiler running, check for cracks at  ttings and joints.

What to do if you smell gas: Do not try to light the appliance. Do not touch any electrical switch. Do not use any phone in the building. Leave building and contact gas supplier from neighbor’s phone. If you cannot reach gas supplier, phone the

 re department.

After initial start-up by quali ed personnel, linkage, control settings, and fuel pressures should not be readjusted.

4 CAUTION

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.

Daily Maintenance and Inspection Schedule

Daily maintenance and inspection must include the following:

1. Observe operating temperature and general conditions.

2. Make sure that the  ow of combustion and ventilating air to the boiler is

not obstructed.

3. Make sure boiler area is free and clear of any combustible materials, including  ammable vapors and liquids.

Monthly Maintenance and Inspection Schedule

Monthly maintenance and inspection must include the following:

1. Inspect the air intake and exhaust vent pipes for broken seals at the joints.

2. Inspect the screens on the air intake and exhaust vent terminal and make sure they are free of dirt or any foreign matter which may block the terminals.

3. Check air intake and exhaust vent outlet for any blockage or restrictions.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

4-2

4. Check for any leaks in exhaust piping.

5. To prevent scale or corrosion in boiler and associated piping, make up water must be kept to a minimum. This is best achieved by ensuring:

SECTION 4 PHW-IOM-2013-0214 MAINTENANCE

§ Immediate repair of all leaks.

§ Maintenance of system pressure.

6. Check condensate trap to be sure it is clear of debris. Also ensure condensate is not backing up into the boilers.

Annual Maintenance and Inspection Schedule

Annual maintenance and inspection must include the following:

1. On units utilizing a  ame rod, the  ame rod should be changed. The  ame rod is located in the top of the boiler for PHW-300-1400, and inside the injector on PHW-2000.

2. Clean/replace  apper valve gaskets.

3. Verify proper combustion and adjust as necessary.

4. Lubricate the modulation motor arms, gas and exhaust butter y valves. Ensure the motion of the valves is smooth.

5. Remove the low water cut o probe and clean. Replace the probe in the boiler.

! 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.

Never use open  ame or other sources of ignition to check for gas leaks.

A defective boiler can cause injury. Do not operate a boiler that is defective, or has any missing parts. Do not attempt repairs or any other maintenance work that you do not understand.

Never store or use gasoline or other  ammables in the vicinity of this appliance.

6. Change the spark plug (see Figures 53 and 54).

7. Check air intake and exhaust vent outlet for any blockage or restrictions.

8. Check for any leaks in exhaust piping.

9. Check for any leaks in the heating system or boiler piping.

10. Check the air intake and exhaust vent piping for sagging.

11. Follow purge procedure outlined in this manual.

12. Follow start up procedure outlined in this manual.

13. With the boiler running, check for visible cracks at  ttings and joints.

14. Check for any blockages in condensate lines, and condensate trap. If a pH Neutralization Kit has been installed, check quantity of media in kit.

NOTE: ´ Should you suspect that the boilers  ue passage ways have become

blocked, contact your Fulton representative.

NOTE: ´ On models PHW300 through PHW1400 the spark plug is located in the top

of the boiler. In PHW2000 the spark plug is located in the gas injector behind the air  apper, and requires a spark plug removal tool, which is supplied with each PHW2000.

Do not use this boiler if any part has been under water. Immediately call a

quali ed service technician.

4 CAUTION

Use caution when using any cleaning solutions. Refer to local regulations for proper cleaning solution disposal.

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

NOTE: ´ Pulse hydronic loops should be con gured so that each boiler does not

cycle more than 12,000 times per year. Warranty may be void if excessive cycling is apparent.

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

4-3

MAINTENANCE PHW-IOM-2013-0214 SECTION 4

4 CAUTION

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

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

FIGURE 53 - PULSE SPARK PLUG

4-4

FIGURE 54 - PULSE MAINTENANCE

After All Repairs and Maintenance

1. Follow “Pre-Start Check List” provided with the unit, and all Safety Checks.

2. Fire the Boiler and perform combustion check.

3. Make any necessary adjustments.

SECTION 4 PHW-IOM-2013-0214 MAINTENANCE

Troubleshooting

Use the following table as a guide to troubleshooting your boiler.

Problem Cause Check

Check fuse or circuit breaker. Reset or replace, as neces-

sary.

For all models check to see if on/off switch has loose wires.

Try adjusting sensitivity of switch or replace.

Check fan for operation. Replace if necessary.

Check for carbon buildup, cracks in porcelain.

Check for bad ground, or bad control. Replace control.

Check for blockage of air inlet line and remove.

Check for carbon buildup, moisture, cracks in porcelain.

Check for proper gab (.050”-.060” for Champion spark

plug). Clean or replace as necessary.

Check connections to all components.

Check that the setpoint is set higher than temperature of

the boiler water.

Check to see if the copper tubing on the air valve housing

is securely connected.

Check fuse or circuit breaker. Reset or replace, as neces-

sary.

Check for bad ground, or bad control. Replace control.

Check adjustment of pressure switch number 2. It should

be set at 1.5” w.c. Replace if necessary.

Check connections to all components.

Check to see if the ﬂ appers on the air valve plate are

placed correctly (covering the holes).

Check to see if the ﬂ appers on the gas valve plate are

placed correctly (covering the holes).

Check for blockage in exhaust piping and remove.

Reset main control panel box on ﬂ ame failure.

Check to see if the ﬂ appers on the air valve plate are

placed correctly (covering the holes).

Check to see if the ﬂ appers on the gas valve plate are

placed correctly (covering the holes).

Check for blockage in air inlet line and remove.

Starting or Purge Failure

Flame Failure

Poor Combustion

Power Supply

On/Off Switch

Bad Air Switch

Bad Fan

Flame Rod

Main Control

Plugged Air Inlet

Spark Plug

Loose Wire Connection

Setpoint

Loose Tubing

Power Supply

Main Control

Proof of Flame Switch

Loose Wire Connection

Air Flappers

Gas Flappers

Plugged Exhaust Line

In all Cases:

Air Flappers

Gas Flappers

Plugged Air Inlet

NOTE: ´ If air or gas  apper material is excessively dirty, they may stick in one position. Replace if excessively dirty.

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

4-5

MAINTENANCE PHW-IOM-2013-0214 SECTION 4

4 CAUTION

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

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

Reviewing Diagnostics on SOLA Control

From the Status Summary screen press Diagnostics (see Figure 55) .

FIGURE 55 - ACCESSING DIAGNOSTICS

1. Pressing Burner I/O will place you into screen shown in Figure 56. From here you can see the inputs being made and/or are open. A green light next to the input indicates the control’s input is made or satis ed, a gray circle indicates the input is not satis ed. This is also a helpful trouble shooting screen.

4-6

FIGURE 56 - I/O STATUS SCREEN

2. Pressing Digital I/O will place you into screen shown in Figure 57. From here you can see speci c information what inputs are/are not being made.

SECTION 4 PHW-IOM-2013-0214 MAINTENANCE

4 CAUTION

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

All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local

FIGURE 57 - I/O STATUS DETAIL

¡ Taking Screen Shots

Using the Screen Shot function of the SOLA control can be a useful tool for troubleshooting. A USB port in the back of the display will accept a small memory stick or thumb drive for transferring screen shots from the display.

Fulton Representative.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

FIGURE 58 - ACCESSING SETUP

At most locations in the display parameters, there is an icon of a camera in the upper left of the screen. By pressing this icon, a snapshot of the screen is captured and saved to the display. To transfer these snapshots to a memory stick or thumb drive, perform the following:

1. From the Home Screen, press Setup in the lower right hand corner. See Figure 58.

2. Press Display Diagnostics. See Figure 59.

3. Press Screen Snapshot. See Figure 60. This is the screen from which you can copy screen shots to a thumb drive.

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

4-7

MAINTENANCE PHW-IOM-2013-0214 SECTION 4

4. Select an existing screen shot in the list and then select Copy to USB. Selecting View allows you to look at a particular screen shot before you copy it. See Figure 61.

FIGURE 61 - SCREEN SNAPSHOT LIST SCREEN

FIGURE 59 - SETUP SCREEN

4-8

FIGURE 60 - DISPLAY DIAGNOSTICS SCREEN

WARRANTY & PARTS

INTRODUCTION

INSTALLATION

1 2

OPERATION MAINTENANCE

WARRANTY & PARTS

3 4

5

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

5-1

WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5

Standard Warranty for Fulton Pulse Boilers Models PHW with Carbon Steel Exhaust Pipes

Ten (10) Year (120 Month) Thermal Shock Warranty

Fulton Heating Solutions guarantees the Pulse hot water pressure vessel against thermal shock for a period of ten (10) years when the boiler is installed as a closed loop hot water boiler and is operated per the Installation and Operation Manual. This guarantee will cover damage due to thermal shock, such as leaks in the heat exchanger. This guarantee does not cover damage

due to corrosion, scaling, sooting or improper installation or operation. The inlet and outlet water temperature di erential across the boiler cannot exceed 100°F.

Ten (10) Year (120 Month) Prorated Flue Gas Condensate Corrosion and Material and Workmanship Warranty

The pressure vessel is covered against  ue gas condensate corrosion and defective material or workmanship for a period of ten (10) years from the date of shipment from the factory according to the schedule below. Fulton will repair or replace F.O.B.

factory any part of the equipment, as de ned above, provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. This warranty covers any failure caused by defective material or workmanship; however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler be installed in a closed loop as outlined in the Installation and Operation Manual.

Year Prorated Schedule

0-7 100%

8 50%

9 30%

10 20%

Parts Warranty

Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within 18 months of shipment from the factory or 12 months from start-up (whichever comes  rst), provided the equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton’s Quality Assurance Department.

General

Fulton shall be noti ed in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if installed, operated, and maintained as outlined in the Fulton Installation and Operation Manual. No Sales Manager or other representative of Fulton other than the Quality

Manager or an o cer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied,

including but not limited to the implied warranties of merchantability and  tness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of pro ts or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective. Excessive cycling will reduce the life of ANY boiler. Verify that your system is properly designed and check cycling rate according to maintenance procedures listed in this manual. To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.

2013-0214

5-2

SECTION 5 PHW-IOM-2013-0214 WARRANTY & PARTS

Standard Warranty for Fulton Pulse Boilers Models PHW with Duplex Stainless Steel Exhaust Pipes

Ten (10) Year (120 Month) Thermal Shock Warranty

Fulton Heating Solutions guarantees the Pulse hot water pressure vessel against thermal shock for a period of ten (10) years when the boiler is installed as a closed loop hot water boiler and is operated per the Installation and Operation Manual. This guarantee will cover damage due to thermal shock, such as leaks in the heat exchanger. This guarantee does not cover damage

due to corrosion, scaling, sooting or improper installation or operation. The inlet and outlet water temperature di erential across the boiler cannot exceed 100°F.

Ten (10) Year (120 Month) Prorated Flue Gas Condensate Corrosion and Material and Workmanship Warranty

The pressure vessel is covered against  ue gas condensate corrosion and defective material or workmanship for a period of ten (10) years from the date of shipment from the factory according to the schedule below. Fulton will repair or replace F.O.B.

factory any part of the equipment, as de ned above, provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. This warranty covers any failure caused by defective material or workmanship; however, waterside corrosion or scaling is not covered. Therefore, it is imperative that the boiler be installed in a closed loop as outlined in the Installation and Operation Manual.

Year Prorated Schedule

0-7 100%

8 50%

9 30%

10 20%

Parts Warranty

Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department.

General

Fulton shall be noti ed in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if installed, operated, and maintained as outlined in the Fulton Installation and Operation Manual. No Sales Manager or other representative of Fulton other than the Quality

Manager or an o cer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied,

including but not limited to the implied warranties of merchantability and  tness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of pro ts or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective. Excessive cycling will reduce the life of ANY boiler. Verify that your system is properly designed and check cycling rate according to maintenance procedures listed in this manual. To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality

Assurance department for review and approval.

2010-0311

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

5-3

PARTS & WARRANTY PHW-IOM-2013-0214 SECTION 5

! WARNING

Use of non-factory authorized replacement parts is not recommended for this equipment. Use of non-factory authorized parts may jeopardize safety and system performance, and voids the product warranty.

Parts

Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial number of your Fulton boiler ready. Factory-direct replacement parts must be used to ensure proper equipment operation and adherence with warranty requirements. Contact Fulton Companies at (315) 2985121 for further information.

Parts list and availability subject to change without prior notice.

5-4

SECTION 5 PHW-IOM-2013-0214 WARRANTY & PARTS

¡ PARTS

PHW Part # Description

2-30-000232 Air switch-purge fan

2-30-001334 Air switch -proof of ﬂ ame x x x x x x x x 2-30-000290 Blocked intake switch x x 2-30-000291 Blocked intake switch x x x x 2-30-001360 Blocked exhaust switch x x x x x x x x 2-12-000551 Air ﬂ apper gaskets (replaced 2-12-553) x x x x x x x 2-12-000554 Air ﬂ apper gaskets x 2-22-000181 Air ﬂ apper spacer - .030 x x x x x

2-22-000182 Air ﬂ apper spacer - .050

2-22-000183 Air ﬂ apper spacer - .040

2-22-000186 Air ﬂ apper spacer - .060 x LP 2-22-000187 Air ﬂ apper spacer - .060 x 2-22-000188 Air ﬂ apper spacer - .070 2-22-000125 Air ﬂ apper screw 8-32 x 1-1/4 x x x x x x x x 2-22-000085 Air ﬂ apper nuts 8-32 x x x x x x x x 2-22-000038 Air ﬂ apper lock washer x x x x x x x x

2-22-000083 AVK Nut for air ﬂ apper assy

2-12-000900 Air ﬂ apper mounting gaskets x 7-37-000120 Air ﬂ apper metering plate assy x 7-37-000150 Air ﬂ apper metering plate assy x x 7-37-000124 Air ﬂ apper metering plate assy x

7-37-000123 Air ﬂ apper metering plate assy

7-37-000125 Air ﬂ apper metering plate assy

7-37-000008 Air ﬂ apper metering plate assy

2-11-000089 Air ﬂ apper housing only - 3” hub x x 2-11-000090 Air ﬂ apper housing only - 4” hub x x x x x 5-11-000095 Air ﬂ apper housing only x 2-12-000556 Air ﬂ apper housing o-ring x x x x x x x x 2-40-000251 Aquastat Operating x x x x x x x x 2-40-000250 Aquastat Hi Limit w/MR 130-270 Deg F x x x x x x x x 2-30-000205 Aquastat immersion well - #121371A x x x x x x x x 2-40-000274 Aquastat Hi Limit w/MR 100-240 Deg F x x x x x x x

2-40-000294 Aquastat Hi Limit w/MR 100-200 Deg F

2-40-000220 Gas valve actuator w/P.O.C. - #V4055D1043

2-40-000214 Gas valve actuator - #V4055A1031 x x x x x x x x 2-30-000310 Gas valve - motorized - 1” - #V5055A1004 x x x x 2-30-000311 Gas valve - motorized - 1-1/4” - #V5055A1012 x x 2-30-001143 Gas valve - motorized - 1-1/2” - #V5097A1004 x x 2-30-001145 Gas valve - motorized - 1-1/2” - #V5097C1000 x x

300 500 650 750 950 1000 1400 2000

x x x x x x x x

x/LP

x x x x x x x x

x x x x

x x x x x x x x x x x x x x x

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

5-5

WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5

PHW Part # Description

Gas valve w/P.O.C. - motorized - 1-1/2” -

2-40-000253 2-30-000306 Gas solenoid valve - 1” ASCO #8040C4 x x x x 2-30-000307 Gas solenoid valve - 1-1/4” ASCO #8040C5 x x 2-30-000304 Gas solenoid valve - 1-1/2” ASCO #821470 x 2-30-001147 Gas solenoid valve - 1” #V4297A1005 x x x 2-30-001141 Gas solenoid valve - 1-1/2” #V4297A1013 x

2-40-000533 Hi-Low Gas Pressure Switch #804111701

2-30-001139 High Gas Pressure Switch - #C6097B1028 x x x x x x x x

2-30-001140 Low Gas Pressure Switch - #C6097A1020 x x x x x x x x

2-30-003002 Gas butterﬂ y valve - 1” - Eclipse x x x x

2-30-003003 Gas butterﬂ y valve - 1-1/4” - Eclipse x x x

2-30-003020 Gas butterﬂ y valve - 2” - Eclipse x

2-30-000750 Gas pressure regulator - 1” RV61 - Pre 3/10 x x x x

2-30-000105 Gas pressure regulator - 1-1/4” RV61 -Pre 3/10 x x

2-30-000515 Gas pressure regulator - 1-1/4” RV81 -Pre 3/10 x

2-30-000516 Gas pressure regulator - 1-1/2” RV81 -Pre 3/10 x x

2-30-000800 Gas pressure regulator - 1” 210D - Post 3/10

2-30-000678 Gas pressure regulator - 1-1/4” 210D-Post 3/10

2-30-001023 Gas pressure regulator -1-1/2” 210E-Post 3/10

2-30-000174 Gas pressure gauge 0-15” W.C. x x x x x x

7-37-000201 Gas ﬂ apper valve - in union x x x x x x x x

2-22-000130 Gas ﬂ apper spacer .060 (brass) x x x x x x x x

2-12-000552 Gas ﬂ apper gaskets x x x x x x x x

7-57-000126 Gas decoupler x x x

7-57-000125 Gas decoupler x x x x

2-20-000204 Gas oriﬁ ce 3/4” x .312 LP

2-20-000130 Gas oriﬁ ce 3/4” x .437 LP

2-20-000209 Gas oriﬁ ce 3/4” x .460 x

2-20-000208 Gas oriﬁ ce 3/4” x .485 x

2-20-000131 Gas oriﬁ ce 3/4” x .500 x

2-20-000201 Gas oriﬁ ce 3/4” x .525 x LP LP

2-20-000205 Gas oriﬁ ce 3/4” x .540 LP

2-20-000212 Gas oriﬁ ce 3/4” x .570 x

2-20-000202 Gas oriﬁ ce 3/4” x .593 x

2-20-000206 Gas oriﬁ ce 3/4” x .625

2-20-000214 Gas oriﬁ ce 3/4” x .651 x x

2-20-000132 Gas oriﬁ ce 3/4” x .690 x

2-20-000203 Gas oriﬁ ce 3/4” x .718

2-20-000650 Gas oriﬁ ce 2” x .312 LP

2-20-000651 Gas oriﬁ ce 2” x .437 LP

2-20-000652 Gas oriﬁ ce 2” x .460 x

2-20-000652 Gas oriﬁ ce 2” x .460 (post 05/2003)

2-20-000653 Gas oriﬁ ce 2” x .485 x

#V5055C1059 x

300 500 650 750 950 1000 1400 2000

x x x x

x x

x

5-6

SECTION 5 PHW-IOM-2013-0214 WARRANTY & PARTS

PHW Part # Description

2-20-000655 Gas oriﬁ ce 2” x .500

2-20-000656 Gas oriﬁ ce 2” x .540

2-20-000656 Gas oriﬁ ce 2” x .540 (post 05/2003) x LP LP

2-20-000657 Gas oriﬁ ce 2” x .525 LP

2-10-400211 Gas oriﬁ ce 2” multi-port LP

2-10-400219 Gas oriﬁ ce 2” multi-port x

2-10-400212 Gas oriﬁ ce 2” multi-port x

2-10-400217 Gas oriﬁ ce 2” multi-port x

2-10-400218 Gas oriﬁ ce 2” multi-port LP

2-10-400216 Gas oriﬁ ce 2” multi-port (factory) x

2-10-400222 “New style” gas oriﬁ ce 2” multi-port x

5-10-400207 Blank brass oriﬁ ce slug 2”

Gas injector assy (need stamped series “letter” to

7-52-002000

7-52-002001 Injector assembly - all fuels LP

7-20-006000 4” Butterﬂ y valve assembly - exhaust modulated x x x x x

7-20-006010 6” Butterﬂ y valve assembly - exhaust modulated x

7-20-006005 6” Exhaust butterﬂ y assy - PHW2000 QT model x

2-12-000701

2-40-000722 Mod motor - M7284Q1009 x x x x x x x x

2-40-000863 Mod temp control - UT32A x x x x

2-40-000801 Type “J” Thermocouple 4” probe

2-40-000830 Type “J” Thermocouple wire per Ft.

2-40-000384 Siemens temp control - RWF40

2-40-000386 Siemens outdoor sensor for RWF40 control

2-40-000425 Mod Temp control - #T771J1050 outsideRS x x x x x x x

2-40-000941 Outdoor Air Temp Sensor

2-30-000201 Press/temp gauge 0-100psi-70-320F x x x x x x x

2-30-000203 Press/temp gauge 0-300psi-70-320F x x x x x x x

2-30-000445 Purge blower motor/fan x x x x x x x

2-30-001337 Purge fan-G185 x

2-40-002000 Purge fan motor-1/2HP, 115/230/60/1, 3450rpm x

2-40-000321 RM7865C1007 Programmer x x x x x x x x

2-40-000268 R7847A1041 Ampliﬁ er x x x x x x x x

2-40-000270 Base for RM7865 Programmer - #Q7800A1013 x x x x x x x x

2-40-000272

2-40-000923 SOLA Flame Control x x x x x x x x

2-40-000932 SOLA Display x x x x x x x x

2-40-000931 SOLA Flame Rod

2-45-000914 Plug Set for SOLA x x x x x x x x

2-40-000908 10K ohm Sensor x x x x x x x x

2-40-000625 24v Power Supply / Transformer x x x x x x x x

2-45-000060 4” x 4” Handy Box x x x x x x x x

2-30-000120 Safety Valve 3/4” X 1” 30# x x x x x x

2-30-000121 Safety Valve 3/4” X 1” 60# x x x x x x x

order) x

Exhaust butterﬂ y gasket 9” OD x 6-9/16” ID - QT model x

Display module for RM7865 Programmer #S7800A1019 x x x x x x x x

300 500 650 750 950 1000 1400 2000

x

X

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

5-7

WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5

PHW Part # Description

2-30-000145 Safety Valve 3/4” X 1” 100# x x x x x x x

2-30-000020 Safety Valve 3/4” X 1” 125# x x x x x x x x

2-30-000166 Safety Valve 3/4” X 1” 160# x x x x x x x x

2-30-000851 Safety Valve 1” X 1-1/4” 30# x

2-30-000951 Safety Valve 1” X 1-1/4” 60# x x

2-30-000269 Safety Valve -1 1/4” X 1-1/2” 160#

2-30-000266 Safety Valve 1-1/4” X 1-1/2” 60#

2-30-000221 Safety Valve 1-1/4” X 1-1/2” 30# x

2-20-000090 Spark plug x x x x x x x x

2-20-000093 Gasket for spark plug - x x x x x x x x

2-45-000017 Spark plug & Flame Rod wire per foot x x x x x x x x

2-45-000149 Wire heat cover per foot x x x x x x x x

2-45-000159 Plastic wrap per foot x x x x x x x x

2-20-000047 Spark plug boot - orange silicone x x x x x x x

2-45-001200 Spark plug crimp on connector x x x x x x x x

2-45-001124 Spark plug terminal connector x

2-30-002330 Spark plug boot w/centering ring x

4-57-000520 Spark plug connector retroﬁ t kit x

5-11-400090 Spark plug bushing 3/4” NPT, brass x x x x x x x x

2-40-001011 Flame rod - #C7009A1009 x x x x x x x x

2-35-000879 Flame rod bushing 1/2” x 1/8” x x x x x x x x

3-20-000090 Spark plug assembly x

2-20-002000 Porcelain ext. rod for spark plug assy x

5-10-001821 Connector for spark plug assy x

5-10-001822 Connector for ﬂ ame rod x x x x x x x x

2-30-000234 Grommet - spark plug wire x x x x x x x

2-40-000082 Ignition transformer 115/60 - #A06SC2 x x x x x x x x

2-40-000151 Time delay relay - #KRDB420 x x x x x x x x

2-45-000469 Time delay relay base x x x x x x x x

2-45-000468 Time delay relay 5 min. 120V - #HRDM415M x x x x x x x x

2-40-000153 8 sec TDR relay (ﬂ ame rod) - #KRDM418S x x x x x x x x

2-40-000121 Time delay relay, .1-10 sec. 120V - #KRD1420 x x x x x x x x

2-45-000101 Terminal block x x x x x x x

2-40-000880 Terminal block - Type “J” Thermocouple x x x x x x x x

2-45-000020 Din rail - per foot x x x x x x

2-40-000131 Ice cube relay 120V - #700HA32A1 x x x x x x x x

2-40-000096 Base for ice cube relay - #700HN125 x x x x x x x x

2-40-000562 Ice cube relay 24V - #700HA32A24

2-40-000200 Motor starter relay - #R4242B1005 x x x x x x x x

2-40-000421 Fulton burner LWCO Relay 120V x x x x x x x

2-40-001021 Fulton burner LWCO Relay w/ test function x x x x x x x

2-40-000423 Base for LWCO relay - #OT11-PC x x x x x x x x

2-12-000090 Retainer spring for LWCO relay x x x x x x x x

MM750P-MT-120 LWCO with 3/4” NPT, Test &

2-40-000418

2-40-000419 MM LWCO w/MR 120v

Reset

300 500 650 750 950 1000 1400 2000

5-8

SECTION 5 PHW-IOM-2013-0214 WARRANTY & PARTS

PHW Part # Description

2-20-000023 Low water probe 3” x x x x x x x x

2-20-000108 Water probe for exhaust decoupler-13”

2-20-000012 Water probe for exhaust decoupler - 11-1/4”

2-20-000109 Water probe for exhaust decoupler-15” x x

2-45-000091 On/off toggle switch x x x x x x x

2-45-000339 Green 3-position switch light x x x x x x x x

2-45-000307 Green 2-position on/off switch light x x x x x x x x

2-45-000022 Green 3-position switch (post 2/2010) x x x x x x x x

2-45-000314 Black 4-position switch x x x x x x x x

2-45-000300 N/O contact block - #3SB3400-0B x x x x x x x x

2-45-000269 N/C contact block - #3SB3400-0C x x x x x x x x

2-45-000700 Double contact block (1) N/O and (1) N/C x x x x x x x x

2-45-000701 Double contact block (2) N/O - #3SB3400-0D x x x x x x x x

2-45-000702 Double contact block (2) N/C - #3SB3400-0E x x x x x x x x

2-45-000305 Red pushbutton low water reset light x x x x x x x x

2-45-000411 Red ﬂ ame failure pilot light - #3SB3248-6BA20 x x x x x x x x

2-45-000412 Green call for heat pilot light - #3SB3248-6BA40 x x x x x x x x

2-45-000203 Light bulb only S&S - 120v x x x x x x x x

2-45-000212 Black 3-position switch x x x x x x x x

2-35-000850 Black panel latch x x x x x x x x

2-20-000079 Magnesium Anode 3/4” (All PDWH)

300 500 650 750 950 1000 1400 2000

x x x x x x

Accessories

5-60-000130 Instruction Manual

4-57-000440 Condensate drain kit x x x x x x x x

2-10-000168 Condensate drain ﬂ oat assembly x x x x x x x x

5-20-000614 Condensate drain TEE assembly - mod x x x x x x x x

2-35-000863 Isolation cube 3” x 2” x 2” x x x x x x

2-35-000835 Isolation cube 3” x 4” x 2” x x

2-35-000864 Isolation spring - green x x x

2-35-000865 Isolation spring - grey x x x x

2-30-000651 Isolation spring - red x

2-35-000989 Isolation spring - brown QT model only x x

2-35-000612 Seismic iso spring - green x x x

2-35-000611 Seismic iso spring - grey x x x x

2-30-000653 Seismic iso spring - red x

2-12-001007 Air Decoupler Door Gasket 16-1/2” 16-1/2” x 3/8” x x

2-12-001006 Air Decoupler Door Gasket 15-1/2” x 3/8” x x x

2-12-001010 Air Decoupler Door Gasket 13-7/8” x 3/8” x x x

2-12-001014 Air Decoupler Door Gasket 21-7/8” x 16-7/8” x 2” x

2-12-000555 Front Panel Door Gasket x x x x x x x x

2-35-000861 2” x 14” ﬂ ex connector - water x x x x x x

2-35-000862 2-1/2” x 16” ﬂ ex connector - water x

2-30-000550 4” x 16” ﬂ ex connector water - ﬂ anged x

2-35-000531 1” x 16” gas ﬂ ex connector x x x x

x x x x x x x x

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

5-9

WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5

PHW Part # Description

2-35-000532 1-1/4” x 16” gas ﬂ ex connector x x

2-35-000801 1-1/2” x 16” gas ﬂ ex connector x x

2-30-000836 Steam hose - 1-1/4” ID x 1-3/4” OD - con drain x

2-12-001000 Insulation - 2” x 24”W x 48”L /sheet

2-30-000498 MM ﬂ ow switch - #FS-4-3-P x x x x x x x x

2-45-000040 1/2” Knockout plug x x x x x x x x

4-57-000500 Air spacer kit (old style) x x x x

4-50-RK0420 Air ﬂ apper repair kit x x x x x x x x

8-00-002000 Spark plug removal tool - black x

8-00-002001 Flame rod removal tool - smoky ash x

8-00-000048 Oriﬁ ce removal tool for 2” NPT multi-port oriﬁ ce x x x x x x x x

8-00-000049 Air ﬂ apper housing removal tool x x x x x x x

2-40-000302 Display case for S7800A module - #206311 x x x x x x x x

2-23-000295 Spray Paint - Smoky Ash - 6oz can - (post 2009) x x x x x x x x

2-23-000172 Spray Paint - Tech Tan - 6 oz can x x x x x x x x

4-23-000016 Liquid Paint - Tech Tan - quart x x x x x x x x

2-35-000799 4” PVC adaptor - air intake x x x x x

2-35-000819 6” PVC adaptor x

5-10-CH2765 4” C.S. mufﬂ er - intake x x x x x x x

5-10-CH2755 4” S.S. mufﬂ er - exhaust x x x x x x x

5-10-CH2780 6” C.S. mufﬂ er - intake x

5-10-CH2775 6” S.S. mufﬂ er - exhaust x

2-35-000033 3” x 3” Fernco coupling -intake - #105633 x x

2-35-000061 4” x 3” Fernco coupling - intake - #105643 x x

2-35-000827 4” x 4” Fernco coupling - intake - #105644 x x x x x x x

2-35-000796 4” x 3” Adaptor for exhaust x x x x x x x x

2-35-000855 4” x 3” PVC reducer x x x x x x x x

4-57-000510 Panel retroﬁ t kit for vibration control x x

2-12-000200 Strip-N-Stick (Gray) - Door Seal 1” x x x x x x x x

2-60-000114 High Temp Red Silicone Sealant 10oz. RTV736 x x x x x x x x

8-00-000101 Material Handling Tool x

2-12-001020 Air decoupler insulation set (foil-faced) x x

2-12-001021 Air decoupler insulation set (foil-faced) x x

2-12-001022 Air decoupler insulation set (foil-faced) x

2-12-001023 Air decoupler insulation set (foil-faced) x

4-50-000004 Pulse QT 4” McGill Air Flow Kit

4-50-000005 Pulse QT 6” McGill Air Flow Kit

4-50-000006 Pulse QT 8” McGill Air Flow Kit

4-50-000008 PH Neutralization Kit x x x x x x x x

2-30-001580 Magnesium oxide/per bag x x x x x x x x

4-50-SP0401 Standard spare parts kit x x x x x x x

4-50-SP0402 Extended spare parts kit x x x x x x x

4-50-SP0405 Standard spare parts kit x

4-50-SP0406 Extended spare parts kit x

NOTES:

300 500 650 750 950 1000 1400 2000

5-10

SECTION 5 PHW-IOM-2013-0214 WARRANTY & PARTS

PHW Part # Description

Standard spare parts kits include (1) air ﬂ apper gasket set, (1) gas ﬂ apper gasket set, (1) spark plug and (1) ﬂ ame rod.

Extended spare parts kits include (1) air ﬂ apper gasket set, (1) gas ﬂ apper gasket set, (1) spark plug, (1) ﬂ ame rod, and

(1) programmer control.

Heat Fab venting material available - consult factory

300 500 650 750 950 1000 1400 2000

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

5-11

WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5

THIS PAGE INTENTIONALLY LEFT BLANK

5-12

SECTION 5 PHW-IOM-2013-0214 WARRANTY & PARTS

THIS PAGE INTENTIONALLY LEFT BLANK

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

5-13

WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5

THIS PAGE INTENTIONALLY LEFT BLANK

5-14

No part of this Installation, Operation, and Maintenance manual

may be reproduced in any form or by any means without

permission in writing from the Fulton Companies.

Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal

Corporation are part of the Fulton Group of Companies, a global manufacturer

of steam, hot water and thermal  uid heat transfer systems.

The heat transfer innovators.

The Fulton Companies

972 Centerville Road, Pulaski, NY 13142 Call: (315) 298-5121 • Fax: (315) 298-6390

www.fulton.com

PHW-IOM-2013-0214

Fulton Pulse HW Fully Condensing Hydronic Boiler User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual