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EXE-IOM-230112
Overview .............................................................................................................. 1-2
Warnings & Cautions ............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Product Overview ................................................................................................. 2-2
Placement & Rigging ........................................................................................... 2-3
Clearances and Serviceability .............................................................................. 2-5
Install Boiler Trim ................................................................................................. 2-5
Install Water Piping .............................................................................................. 2-6
VARIABLE PRIMARY PIPING ARRANGEMENT ............................................................................2-7
PRIMARY-SECONDARY PIPING ARRANGEMENT ......................................................................2-10
Meet Water Chemistry Requirements ................................................................ 2-11
PREVENT OXYGEN CONTAMINATION ........................................................................................2-12
ELIMINATE SYSTEM AIR ............................................................................................................2-12
Fill the Boiler With Water ................................................................................... 2-12
Gas Supply Piping .............................................................................................. 2-12
INLET GAS PRESSURE ................................................................................................................2-13
LINE GAS PRESSURE REGULATION ............................................................................................2-13
GAS PIPING INSTALLATION .......................................................................................................2-14
COMPONENTS REQUIRING VENTILATION TO THE OUTDOORS .................................................2-14
Install Condensate Drain Trap ............................................................................. 2-16
Install pH Neutralization Kit ............................................................................... 2-17
Venting Requirements ....................................................................................... 2-18
Combustion Air Intake ....................................................................................... 2-19
COMBUSTION AIR SUPPLY FROM THE BOILER ROOM ..............................................................2-20
COMBUSTION AIR DUCTED FROM THE OUTDOORS..................................................................2-21
Flue Gas Exhaust Venting ................................................................................... 2-22
Common Flue Gas Venting Layouts .................................................................... 2-23
COMMON VENTING EXHAUST BACKFLOW PREVENTION .........................................................2-25
Venting Terminations ......................................................................................... 2-26
WALL THIMBLE INSTALLATION .................................................................................................2-26
ROOF VENT TERMINATION .........................................................................................................2-27
SIDE WALL VENT TERMINATION ................................................................................................2-27
Removing an Existing Boiler ............................................................................. 2-31
Assembly of Fulton Multi-Skid Systems............................................................. 2-31
Electrical Connections and Devices .................................................................... 2-32
LOCATIONS FOR FIELD WIRING .................................................................................................2-37
ELECTRICAL AND CONTROLS OPTIONS .....................................................................................2-37
Questions? Please Contact Your Local Manufacturer's Representative
1-1
Perform Pre-Start-Up Inspection ......................................................................... 3-2
Fill and Purge the System..................................................................................... 3-2
Commission The Boiler ......................................................................................... 3-3
SYSTEM DESIGN AND BOILER OPERATION .................................................................................3-3
2-1
Adjusting and Verifying Combustion ................................................................... 3-4
PREPARATIONS BEFORE SETTING COMBUSTION .......................................................................3-4
LIGHTING THE BURNER AND SETTING COMBUSTION ................................................................3-5
VERIFYING SAFETIES AND IGNITION RELIABILITY .....................................................................3-7
UPON SUCCESSFUL COMPLETION ...............................................................................................3-7
Combustion Parameters ...................................................................................... 3-8
Using the PURE Control™ Interface ...................................................................... 3-9
NAVIGATION .................................................................................................................................3-9
PURE Control™ Menu Screens ............................................................................ 3-10
BOILER .......................................................................................................................................3-10
ALARM HISTORY ........................................................................................................................3-10
CIRCULATION .............................................................................................................................3-10
LEAD/LAG ...................................................................................................................................3-11
PID ..............................................................................................................................................3-12
TEMPERATURE ...........................................................................................................................3-13
CONFIGURATION ........................................................................................................................3-14
Testing Safety Devices ........................................................................................ 3-15
PERFORM TEST OF LIMIT CONTROLS ........................................................................................3-15
PERFORM TEST OF LOW GAS PRESSURE SWITCH ....................................................................3-15
PERFORM TEST OF HIGH GAS PRESSURE SWITCH ...................................................................3-15
PERFORM TEST OF LOW WATER CUT OFF .................................................................................3-15
Maintenance
General ................................................................................................................. 4-2
Tool List ................................................................................................................ 4-3
Daily Inspection Schedule ................................................................................... 4-4
Weekly Maintenance Schedule ........................................................................... 4-4
Monthly Maintenance Schedule .......................................................................... 4-4
Replacing or Updating the Boiler Control ............................................................ 4-4
Annual Maintenance Schedule ............................................................................ 4-5
Removing and Cleaning Burner Assembly .......................................................... 4-6
Removing and Cleaning Flame Rod ..................................................................... 4-7
Verification of Ignition Electrode Gap .................................................................. 4-8
After All Repairs and Maintenance ...................................................................... 4-9
Parts Diagrams ................................................................................................... 4-10
Troubleshooting ................................................................................................. 4-16
Pre-Commissioning Installation Checklist ........................................................... 5-3
Installation & Operation "Start-Up" Report ......................................................... 5-5
Annual Maintenance Checklists .......................................................................... 5-7
Notes .................................................................................................................. 5-17
TABLE OF CONTENTS
3-1
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