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MAINTENANCE
Troubleshooting
Use the following table as a guide to troubleshooting your boiler.
PROBLEM
No Power / Control Does
not Illuminate
Nuisance Manual Reset
High Temperature Limit
Lockouts
Boiler Excessively Cycling
4-16
CAUSE
CHECK
Power / Wiring /
Check fusing and replace as necessary.
Connections
Cycle power to the boiler.
Measure incoming voltage to boiler and verify it is in compliance with 120VAC requirements.
Verify control power supply voltage.
Verify all power plugs are fastened securely to control devices.
Verify that the display mounting clips are not over tightened.
Verify wiring between terminal blocks, power supplies and control devices.
Controller/Settings
Verify the setting on the Manual Reset High Limit (MRHL), it must always be higher than the
sum of the temperature setpoint plus off hysteresis value. The factory default setting is 210°F.
Check the supply temperature setpoint setting parameter in the boiler control or Building
Management System setpoint signal where applicable. The closer the setpoint setting is to
the MRHL setting, the higher the likelihood of a lockout.
Installation
Verify balancing valves (if used) have been properly commissioned.
For modular boiler plants, ensure piping is configured reverse return where the first boiler in is
the last boiler out. If the piping configuration is not reverse return, balancing valves should be
installed and properly commissioned to ensure each boiler is receiving relatively equal water
flow.
Verify the boiler is receiving enough flow at the current heat demand for the given hydronic
fluid type and desired delta-T. If calibrated flow meters are not available, flow rate can be
approximated by calculation by observing the delta-T across the boiler heat exchanger at a
given firing rate. See the Fulton "Calculating Flow Rate" Engineering Guide for more details.
Controller/Software
Consult Fulton technical support to verify the latest software version is installed on the
PURE Control.
Verify boiler is configured for automatic operation.
Verify temperature setpoint and on/off hysteresis settings are appropriate at each boiler. A
tighter hysteresis band will increase cycling, relax (increase) this band to reduce cycling.
Verify PID settings are appropriate for boiler application. Note that there are different
PID settings for Local and for Lead/Lag operation. Verify these settings are correct and
matching on each boiler installed.
If a Building Automation is commanding temperature setpoint to the boiler(s), ensure that
any setpoint changes are infrequent and slowly stepped in small increments/decrements.
Rapid changes in temperature setpoint may cause boiler short cycling.
SECTION 4
EXE-IOM-230112
© Fulton Group N.A., Inc. 2023
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