Exhaust Muffler Installation (continued on next page) Air Intake & Exhaust Piping Requirements for the Pulse Boiler Air Intake Supply and Exhaust Vent Installation Vertical Vent Flashing and Installation Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 3...
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Section 4 – Maintenance Before Each Heating Session Recommended Monthly Maintenance Recommended Annual Maintenance Troubleshooting Troubleshooting-Fault Code Diagnosis Troubleshooting-RM7865C without display Honeywell RM7865C Section 5 – Parts & Warranty Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 4...
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Fulton Pulse combustion hydronic heating No Expensive Chimney Needed boilers already meet or exceed most new emission Pulse combustion is self-venting through an AL29-4C standards. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 5...
Section 1 – Safety Warnings & Precautions This manual is provided as a guide to the correct operation and maintenance of your Fulton PulseHW Boiler, and should be permanently available to the staff responsible for the operation of the boiler.
Do not attempt repairs or any other maintenance work you do not understand. Obtain a Service Manual from Fulton or call a Fulton Service Engineer. WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
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Note The Fulton Pulse combustion hydronic heating boiler is not designed for use in systems where water is replenished. Mineral buildup can occur on the heat transfer surfaces and result in over heating and possible failure of the heat exchanger.
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National Fuel Gas Code, ANSI Z223- 1-1991 or latest addenda. In Canada gas installations must be in accordance with the current CAN/CGA B149.1 and .2 and/or local codes. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 12...
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Assembly should be completed within 20 seconds after last application of cement. Do not use hammer to insert pipe. Note A Fulton Pulse boiler should not be connected to a common venting system with other types of gas appliances. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713...
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It is important to know that if the following parameters are altered, the entire set of factory values will be altered: (In) or (UNIT) located in the Input/Output Menu; (AL1) in the Functional Parameters Menu; (A1) in the Operating Parameters Menu. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 14...
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PID or auto tune settings. Note Your Fulton Pulse Combustion Hydronic Boiler has been designed for years of trouble-free performance. To ensure the continued safety and efficiency of the boiler, the schedule of maintenance outlined in this section should be adhered to. The boiler should be inspected annually.
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The following are copies of safety labels and warnings, which are affixed to the Fulton Pulse Combustion Hydronic Boilers. They are reproduced here as a further safety precaution and as a reminder to quickly identify them on the boiler. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713...
75.8 IN 2. Introduction a) The Fulton Pulse combustion hydronic boiler is an automatic gas fired, direct vent boiler. This boiler utilizes pulse combustion principle. It requires no conventional burner controls, no pilot and no chimney. The combustion components are of integral design with the heat exchanger.
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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. 3. The following items are standard trim for Fulton Pulse Combustion Hydronic Boilers: a) Fully Insulated...
Figure 1 Note The Fulton Pulse Hot Water (PHW) Series boiler is designed for use in closed loop heating systems. It is not designed for use in systems where water is replenished. Mineral build up can occur on the heat transfer surfaces and result in equipment failure.
Spring loaded pipe hangers should be used on the air inlet and the flue gas vent. Contact your Fulton Representative for vibration isolation packages designed specifically for your application. Note For installations near “sensitive” areas such as offices, classrooms, or hospital rooms, spring mounts-which fit under the corner of each boiler must be used instead of the cubes.
Tighten the lock nuts on the leveling bolts, thus bolting the spring to the boiler and locking the leveling bolt against turning. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 23...
When the safety relief valve discharge is piped away from the boiler to the point of discharge, there shall be provisions made for properly draining the piping. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 24...
The top connection on the boiler is the OUTLET and must be connected as the supply to the system. c) Connect hot water supply to heating system feed line. d) Connect expansion tank. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 25...
The condensate drain kit is intended to be utilized 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 8 total per drain kit) through a common header.
Failure to keep drain piping lower than this point will result in overflow of the condensate drain. Slope the drain pipe away at a minimum pitch of 1" for every 12 feet. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 28...
6. Attach a 1/4" water supply to the compression fitting on the float. 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 flow preventer to avoid contamination of a potable water supply.
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Gas Pressure Switches: Low pressure switch should not be set less than 50% of manifold pressure. High pressure switch should not be set any more than 150% of the manifold pressure. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 30...
Caution Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Figure 5a Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 31...
Spark plug is energized. Gas valve is energized. k) Flame sensing is proven allowing sequence to continue. Purge Fan shuts off. Pulse combustion process will continue until temperature control is satisfied. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 32...
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HGP-High Gas LWSR-Low Water FF-Panel Light (Flame Pressure Switch Safety Relay Failure) Note: A specific wiring diagram for your unit is provided inside the front door of your boiler. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 33...
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Typical PHW-2000 Electrical Drawing with Optional ModSync Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 34...
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**A minimum 10’ of 4” air intake and exhaust is required for the PHW-1400. Air intake and exhaust configurations over 10’ in length will require 4” for the first 10’ from the boiler and then 6” up to an additional 40’ and four elbows. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 35...
2.5” w.c. (Consult factory for assistance.) 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.) Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 36...
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1/4 turn to distribute cement evenly, continue to insert pipe until it bottoms out. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 37...
Figure 7 18. Intake Muffler Installation a) Follow steps 1-9 above for cementing joints. For best noise attenuation, the muffler should be installed as close to the boiler as possible. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 38...
19. Exhaust Vent Piping Installation Preparation Note A Fulton Pulse boiler should not be connected to a common venting system with other types of gas appliances. a) The boiler is equipped with an exhaust vent connection located at the rear of the boiler.
If air intake or exhaust layouts require upsizing, it is important to keep the first 10 feel closest to the boiler matching the outlet connection size of the boiler. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 40...
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. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 41...
2 feet horizontally from the roof surface, and the lowest discharge opening shall be no lower than the minimum height specified in Fig. 12. These minimum heights may be used provided the vent is not less than 8 feet from any vertical wall. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 44...
See next page Figure 14 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. Figure 13 Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 45...
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. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 46...
5. At this point, the system has been initially filled. However, air pockets may still remain at high points in the system and in heating loops above the level of the combination shut/off purge valve. It is quite possible, Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 47...
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10. When purging is completed, make sure the following are open— combination shut-off/purge valve, shutoff valve to pressure reducing (fill valve), shutoff valve in cold water fill line, and shutoff valve in return line. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 48...
Set the temperature control to the desired setting. d) Open the manual shut off gas valve. e) Close the circuit breaker or the fuse disconnect. Turn the on-off switch to “ON” Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 49...
Replace with a 1/4" NPT to 1/4" compression (or flange) adaptor and a short piece of tubing. Connect a piece of rubber hose from tubing to a manometer. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 51...
Check all controls to insure they are operating properly. Cycle boiler several times by raising and lowering operating temperature on the temperature controller. b) Make sure installation complies with all applicable codes. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 52...
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life. 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.
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Figure 18 2. Starting the Fulton Pulse Combustion Hydronic Heating Boiler a) Open the main gas cock knob counter clockwise 1/4 turn to “ON” position (Figure 19). Figure 19 b) Turn on all electric power to the boiler. c) Set temperature control to desired setpoint.
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Do Not Change Flame Pressure Switch Settings. Caution Should overheating occur or the gas supply fail to shut off, shut off the gas supply at a location external to the boiler. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 57...
AC line frequency error caused by using a 60 Hz device on a 50 Hz line or vice versa. AC line noise that can prevent a sufficient reading of the line voltage inputs. Brownouts caused by a low line voltage. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 58...
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ILK opens, the RM7865 will recycle to PREPURGE only if the selected number of retry attempts is not exceeded. After the eight seconds, the RM7865 will enter the RUN period. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 59...
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1. The main fuel valve and ignition, terminals 8 and 10, are de-energized. The purge fan switch is energized and the POSTPURGE period begins. 2. After the 35 second POSTPURGE period is completed, the RM7865 returns to STANDBY. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 60...
It is important to know that if the following parameters are altered, the entire set of factory values will be altered: (In) or (UNIT) located in the Input/Output Menu; (AL1) in the Functional Parameters Menu; (A1) in the Operating Parameters Menu. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 61...
7. Worksheets a) Use the worksheets to record the values set at site under Customer Value. If the unit is not operating correctly, call your Fulton representative. Have your customer values handy for trouble-shooting. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713...
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Time Unit for Ramp P.SL Protocol Selection Communication Speed Parity Stop Bit Data Length Address RP.T Minimum Response Time TEST Test Control Note: Parameters with bold values only will be used. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 63...
Proportional Band 1.Ic Integral Time 1.Dc Derivative Time 1.DB Dead Band 1.RP Reference Point 1 2.RP Reference Point 2 Reference Deviation Note: Parameters with bold values only will be used. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 64...
9. Return to Auto mode. 9. Siemens RWF40 Control a) Fulton can provide a RWF40 Outdoor Reset Temperature Control as an option. A copy of the Standard program for this control is provided in this manual. Please reference the RWF40 manual provided with the boiler for programming instructions.
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Filter time constant for digital filter, analog input 3 oLLo Lower working range limit -1999 210 stainless steel OLHi Upper working range limit 9999 250 carbon steel Bus Watch Dog Timer Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 66...
Also note that the mod motor and exhaust butterfly valve linkage arms should be parallel. 4. Location of the lock nuts on the linkage rods is not important. d) Linkage Relationships Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 67...
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3. The gas butterfly valve should be used to adjust Low Fire input. The exhaust butterfly valve should be adjusted to set proper combustion. Closing the exhaust butterfly valve will also decrease input slightly. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 68...
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Note The unit will still shut off at setpoint plus 5°F (standard settings). Also, being in manual mode, the temperature control ignores any PID or auto tune settings. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 69...
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Set the temperature back to the Auto setting by pressing the A/M key – the operating and setpoint temperatures will be displayed in the PV and SP displays, respectively. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 70...
Section 4 – Maintenance Note Your Fulton Pulse Combustion Hydronic Boiler has been designed for years of trouble-free performance. To ensure the continued safety and efficiency of the boiler, the schedule of maintenance outlined in this section should be adhered to. The boiler should be inspected annually.
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Note Pulse hydronic loops should be configured so that each boiler does not cycle more than 12,000 times per year. Warranty may be void if excessive cycling is apparent. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 74...
This troubleshooting guide will assist in the diagnosis and correction of minor field problems. It should be used in conjunction with the unit wiring diagram. In any case requiring additional assistance, the Fulton Service Department should be contacted. Problem...
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Check that the operating temperature control is set higher than temperature of the boiler water. Loose Tubing Check to see if the copper tubing on the air valve housing is securely connected. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 76...
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Check to see if the flappers on the Poor Combustion gas valve plate are placed correctly (covering the holes). Plugged Air Inlet Check for blockage of air inlet line and remove. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 77...
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4. During PREPURGE, measure the voltage between terminal 7 and G (ground). 120 Vac should be present. If not, the Block Intake Switch is defective and should be replaced. 5. If fault persists, replace the relay module. Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 78...
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Retrofit For On/Off Application, Flame Rod, 4 Attempts RM 7865B Retrofit Modulated, No Flame Rod 4 Attempts Modulated, Flame Rod RM7865C 4 Attempts Standard Modulated, Flame Rod 1 Attempt Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 79...
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4-50-SP0403 Standard spare parts kit 4-50-SP0404 Extended spare parts kit 4-50-SP0408 Extended spare parts kit w/flame rod 4-50-SP0405 Standard spare parts kit 4-50-SP0406 Extended spare parts kit w/flame rod Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713 Page 88...
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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 profits or business, even if the Fulton Companies has been advised of the possibility of such damages.
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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,...
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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 fluid heat transfer systems.
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