Related Manuals for FULTON PHW 300
Summary of Contents for FULTON PHW 300
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Page 1: Operation 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... -
Page 3: Table Of Contents
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 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 4 TABLE OF CONTENTS PHW-IOM-2013-0214 © The Fulton Companies 2013...
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Page 5: Introduction
INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 6: Overview
Code ANSI Z2231/NFPA 54 latest edition, and the speci c should it replace existing codes or standards which may be instructions in this manual. Authorities having jurisdiction applicable. Fulton reserves the right to change any part of should be consulted prior to installation. this installation, operation and maintenance manual. -
Page 7: Installation
INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 8: Product Overview
The Fulton Pulse combustion hydronic boiler is an automatic gas red, direct jurisdictional/professional codes and vent boiler. This boiler utilizes pulse regulations. combustion principle. It does not... -
Page 9: Placement & Rigging
Placement & Rigging clearances between equipment and combustible materials may result in re. Proper placement of your Fulton product is essential. Correct placement is the rst step to trouble-free installation, operation, and maintenance. CAUTION Adhere to the following for placement and rigging: Do not allow weight to bear on equipment 1. -
Page 10: Boiler Dimensions And Operating Requirements
G. Min. Clearance to Ceiling H. Min. Clearance to Either Side Wall I. Min. Clearance in Front of Boiler J. Min. Clearance Behind Boiler Front View Back View Top View FIGURE 2 PULSE COMBUSTION HYDRONIC BOILER © The Fulton Companies 2013... -
Page 11: Clearances And Serviceability
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... -
Page 12: How To Install Spring Isolation Mounts
Do not install the boiler in an uncontrolled environment where the condensate will be subject to freezing temperatures. NOTE: Contact your Fulton Representative for vibration isolation packages designed speci cally for your application. How to Install Spring Isolation Mounts Adhere to the following for Spring Isolation Mounts (see Figure 4): 1. -
Page 13: How To Install Seismic Spring Isolation Mounts
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... -
Page 14: Install Boiler Trim
“closed-loop” recirculating hot water heating systems. 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). © The Fulton Companies 2013... -
Page 15: Install Water Piping
Multiple Boiler Installation TYPICAL PIPING SYSTEM UNLESS OTHERWISE NOTED, ALL ADDITONAL COMPONENTS SHOWN ARE TYPICAL BOILER (S) ON EACH BOILER DRAIN CONDENSATE DRAIN FIGURE 6 TYPICAL PIPING MULTIPLE BOILER SYSTEM Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 16 2-10 © The Fulton Companies 2013...
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Page 17: Install Condensate Drain
Pulse maintenance schedule. The condensate drain kit is intended for use with any size Pulse unit supplied by Fulton. The 3/4” condensate drain on 3. A condensate collecting tank and condensate pump FIGURE 7 MULTIPLE BOILER CONDENSATE DRAIN INSTALLATION 2-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 18: Install Condensate Drain Piping
Install pH Neutralization Kit CAUTION The pH Neutralization Kit is a Fulton-provided kit designed to bring the pH level The vent line connection on the gas of the boiler’s condensate to a neutral level. It is not a replacement or alternative... -
Page 19: Fulton Ph Neutralizing Kit Without Pump
ISOMETRIC VIEW 11 1/4 1" NPT [286] CONNECTION TO BOILER 1 1/2" PLASTIC FITTING CONNECTION TO DRAIN FRONT VIEW FIGURE 9 FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK 2-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 20: Install Gas Piping
Connect a ground wire to green colored connections, (factory and eld), for gas leaks. Use a soap ground lug in electrical control box. and water solution. 2-14 © The Fulton Companies 2013... -
Page 21: Air Intake Supply Piping Installation Preparation
FIGURE 12 AIR INLET LOCATION 2-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 22: Cementing Joints
3. Clean and dry surfaces to be joined. 4. Test t joint and mark depth of tting on the pipe. 2-16 © The Fulton Companies 2013... -
Page 23: Install Intake Mu Er
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. -
Page 24: Exhaust Muffl Er Installation
(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. 2-18 © The Fulton Companies 2013... -
Page 25: Air Intake & Exhaust Piping Requirements For The Pulse Boiler
(inches) Elbows 10 minimum 35 maximum 10 minimum 35 maximum 10 minimum 35 maximum 1000 10 minimum 35 maximum 1400* 10 minimum 35 maximum 2000 10 minimum 35 maximum 2-19 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 26: Air Intake Supply And Exhaust Vent Installation
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 © The Fulton Companies 2013... -
Page 27: Vertical Vent Flashing And Installation
Fig. 18. These minimum heights may be used provided the vent is not less than 8 feet from any vertical wall. 2-21 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 28 USE OF ISOLATION CUBES OR SPRINGS IS REQUIRED 1/4" TAPPING FOR WATER\ 100 PSI MAXIMUM PROPER TRAP HEIGHT MUST BE ACHEIVED, AS SHOWN IN FIGURE 7 FIGURE 14 TYPICAL CEILING AND ROOF PENETRATION DETAIL 2-22 © The Fulton Companies 2013...
- Page 29 INSTALLATION SECTION 2 PHW-IOM-2013-0214 FIGURE 15 FIRE STOPPING REQUIRED FOR ALL CEILING/FLOOR FIGURE 17 CORRECT ROOF FLASHING INSTALLATION INSTALLATIONS FIGURE 16 FIRE STOPPING 2-23 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 30: Horizontal Installation Wall Penetrations
4. Install two pipe retaining clamps around the intake is 20 inches. as well as vent pipes on both ends of the wall thimble (on the inside and outside of the wall) through which 2-24 © The Fulton Companies 2013... -
Page 31: Horizontal Vent Termination
1. Join the vent termination to the vent pipe outside the building openings unless the venting system is at least 2-25 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 32: After Installation/Prior To Start-Up
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 2-26 © The Fulton Companies 2013... - Page 33 If no pressure drop is detected for a period of two hours under pressure, the 2-27 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 34: Installation Checkpoints
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. 2-28 © The Fulton Companies 2013... -
Page 35: To Correct Input Adjust Gas Pressure Regulator
Fisher. Consult your Authorized Fulton regulator vent. 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 2-29 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 36: Before Leaving The Installation
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. 2-30 © The Fulton Companies 2013... - Page 37 OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 38: Before Start Up
Before Start Up All information in this manual is for Fulton Pulse combustion boilers do not have a pilot. They are equipped with an reference and guidance purposes, ignition device which automatically lights the boiler. Do not try to light the boiler... -
Page 39: Linkage Adjustment For Pulse Modulated Boilers
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. Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 40 LINKAGE RELATIONSHIPS The location of the linkage rods and the speed at which the butter y gas valve Non-Fulton product information is for and butter y exhaust valve opens or closes will determine whether the unit reference purposes only. No Fulton operates smoothly or not.
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Page 41: If The Boiler Doesn't Start
Check for counterclockwise (minimum span). proper water level in the boiler (low water cuto ). 5. Reapply power to the boiler. 8. If the boiler still does not operate, follow these Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 42: Sequence Of Operation For Modulated Pulse Hydronic Boilers
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. © The Fulton Companies 2013... - Page 43 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...
- Page 44 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. © The Fulton Companies 2013...
- Page 45 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...
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Page 46: Changing/Testing Sola High Limit Setpoint
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 Non-Fulton product information is for testing purposes. A change will require Veri cation (see below). -
Page 47: Accessing Lockout History And Clearing Lockouts
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 3-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 48: Procedure For Remote Firing Rate Using A 4 20Ma Signal Single Boiler
Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. - Page 49 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. 3-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 50: Procedure For Lead/Lag With Outdoor Reset With Multiple Boilers
Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. - Page 51 Unapproved modi cations may cause injury, equipment damage, and will void the warranty. FIGURE 36 ACCESSING THE CONFIGURATION MENU FIGURE 37 ADVANCED SETTINGS FIGURE 38 OUTDOOR RESET 3-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 52 (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.
- Page 53 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. 3-17 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 54: Single Boiler Outdoor Reset Programming
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. - Page 55 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 3-19 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 56 Sola base ECOM terminals 1,2, and 3. 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.
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Page 57: Third Party Sola Control
PHW-IOM-2013-0214 Third Party SOLA Control Gateways Fulton o ers (as an option) a Modbus to Bacnet gateway. The Pulse SOLA Control provides the capability of control The gateway will come pre-programmed and wired in one, and/or monitoring by a third party. The standard SOLA control or if desired, all of the boilers. - Page 58 No parity bit 1 stop bit Note: If boilers are daisy chanied together only one BMS connection is required to the master. FIGURE 51 LEAD/LAG OF HYDRONIC BOILERS USING THE SOLA CONTROL MAXIMUM OF 8 BOILERS 3-22 © The Fulton Companies 2013...
- Page 59 OPERATION SECTION 3 PHW-IOM-2013-0214 FIGURE 52 EXAMPLE/TYPICAL ELECTRICAL DIAGRAM 3-23 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 60 OPERATION SECTION 3 PHW-IOM-2013-0214 3-24 © The Fulton Companies 2013...
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Page 61: Maintenance
MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 62: General
Daily, Weekly and Monthly Maintenance and Inspection (Fulton considers the regulations. following to be good practice for any boiler, and is applicable to the full line of Pulse boilers). -
Page 63: Annual Maintenance And Inspection Schedule
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... -
Page 64: After All Repairs And Maintenance
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. FIGURE 53 PULSE SPARK PLUG In order to meet warranty conditions, ensure all appropriate maintenance activities are performed. -
Page 65: Troubleshooting
Plugged Air Inlet Check for blockage in air inlet line and remove. 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... -
Page 66: Reviewing Diagnostics On Sola Control
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. -
Page 67: Taking Screen Shots
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... - Page 68 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 FIGURE 60 DISPLAY DIAGNOSTICS SCREEN © The Fulton Companies 2013...
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Page 69: Warranty & Parts
WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 70: Standard Warranty For Fulton Pulse Boilers
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. -
Page 71: Standard Warranty For Fulton Pulse Boilers
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. -
Page 72: Parts
Fulton Companies. When ordering replacement parts, please have for this equipment. Use of non-factory the model number and serial number of your Fulton boiler ready. Factory-direct authorized parts may jeopardize safety replacement parts must be used to ensure proper equipment operation and and system performance, and voids the adherence with warranty requirements. - Page 73 Gas valve - motorized - 1” - #V5055A1004 2-30-000311 Gas valve - motorized - 1-1/4” - #V5055A1012 2-30-001143 Gas valve - motorized - 1-1/2” - #V5097A1004 2-30-001145 Gas valve - motorized - 1-1/2” - #V5097C1000 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 74 Gas orifi ce 2” x .312 2-20-000651 Gas orifi ce 2” x .437 2-20-000652 Gas orifi ce 2” x .460 2-20-000652 Gas orifi ce 2” x .460 (post 05/2003) 2-20-000653 Gas orifi ce 2” x .485 © The Fulton Companies 2013...
- Page 75 2-40-000908 10K ohm Sensor 2-40-000625 24v Power Supply / Transformer 2-45-000060 4” x 4” Handy Box 2-30-000120 Safety Valve 3/4” X 1” 30# 2-30-000121 Safety Valve 3/4” X 1” 60# Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 76 2-40-000200 Motor starter relay - #R4242B1005 2-40-000421 Fulton burner LWCO Relay 120V 2-40-001021 Fulton burner LWCO Relay w/ test function 2-40-000423 Base for LWCO relay - #OT11-PC 2-12-000090 Retainer spring for LWCO relay MM750P-MT-120 LWCO with 3/4” NPT, Test &...
- Page 77 2” x 14” fl ex connector - water 2-35-000862 2-1/2” x 16” fl ex connector - water 2-30-000550 4” x 16” fl ex connector water - fl anged 2-35-000531 1” x 16” gas fl ex connector Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 78 Pulse QT 8” McGill Air Flow Kit 4-50-000008 PH Neutralization Kit 2-30-001580 Magnesium oxide/per bag 4-50-SP0401 Standard spare parts kit 4-50-SP0402 Extended spare parts kit 4-50-SP0405 Standard spare parts kit 4-50-SP0406 Extended spare parts kit NOTES: 5-10 © The Fulton Companies 2013...
- Page 79 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 5-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 80 WARRANTY & PARTS SECTION 5 PHW-IOM-2013-0214 THIS PAGE INTENTIONALLY LEFT BLANK 5-12 © The Fulton Companies 2013...
- Page 81 WARRANTY & PARTS SECTION 5 PHW-IOM-2013-0214 THIS PAGE INTENTIONALLY LEFT BLANK 5-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 82 WARRANTY & PARTS SECTION 5 PHW-IOM-2013-0214 THIS PAGE INTENTIONALLY LEFT BLANK 5-14 © The Fulton Companies 2013...
- Page 84 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.
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