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MAINTENANCE
PROBLEM
Boiler Excessively Cycling
Main Flame Failure
CPU Error Displayed
4-18
CAUSE
CHECK
Controller/Software
Consult Fulton technical support to verify the latest software version is installed on the
PURE Control.
Verify boiler is con gured for automatic operation.
Verify temperature setpoint and on/o 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 di erent
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.
Maintenance
Verify combustion parameters at all combustion points P1-P9. Adjust as necessary.
Verify su cient supply gas pressure within the requirements of the data plate at the rear
of the boiler. Ensure gas pressure does not drop more than 15% between static (idle) and
dynamic (high re).
Verify manifold gas pressure is within the speci ed requirements. Refer to the factory
Test Fire Report included with the boiler. Note: Test Fire Report parameters are used as a
reference point, site conditions will ultimately dictate what parameters are appropriate for
safe and reliable operation.
Inspect burner, clean according to maintenance instructions if dirty.
Inspect combustion air lter. Replace if dirty.
Verify ame rod wiring and operation; replace as needed.
Using a manometer, measure the draft pressure at the boiler ue gas exhaust outlet
connection during idle, trial for ignition, low re and high re. At all conditions the draft
pressure must be within the limits speci ed in Table 4.
Inspect the intake termination. Ensure it is not obstructed by ice, snow, or debris. Ensure
the intake termination is not subjected to high wind.
Inspect the ue gas exhaust termination. Ensure it is not obstructed by ice, snow, or debris.
Ensure the ue gas exhaust termination is not subjected to high wind.
Ensure Flue Gas Recirculation (FGR) is not occurring by visually witnessing the interaction
of the exhaust and intake terminations during boiler main ame run. FGR will be
evidenced by a vapor plume in the immediate vicinity of the intake termination. If
occurring, this must be immediately corrected.
Possible solutions for FGR include:
• Removing the exhaust termination rain cap (if installed)
• Installing an exhaust termination velocity cone
• Increasing the height of the exhaust termination
• Increasing the horizontal separation of the intake to the exhaust termination
Verify the boiler room is at a neutral pressure relative to the outdoors.
Verify no other mechanical equipment intake or exhaust is installed near the boiler
combustion air intake, such as other boilers, water heaters, air handling equipment, cogen
units and or cooling towers.
Electrical/Wiring
Verify all modules clipped into the back of display are fastened completely and securely.
Replace CPU module and/or display.
SECTION 4
EDR-PURE-IOM-230608
© Fulton Group N.A., Inc. 2023
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