FULTON PDWH750* Installation, Operation And Maintanance Manual
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FULTON PDWH750* Installation, Operation And Maintanance Manual

Gas fired pulse commercial water heaters
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Installation,
Operation And
Maintenance
Manual
December 2009
Rev. C June 2011
Fulton Gas Fired
Pulse Commercial

Water Heaters

*Model PDWH750 is no longer offered but is kept in this manual for
reference purposes on previous equipment purchases.
PDWH750*
PDWH1000

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Summary of Contents for FULTON PDWH750*

  • Page 1: Water Heaters

    Installation, Fulton Gas Fired Operation And Pulse Commercial Maintenance Water Heaters Manual December 2009 Rev. C June 2011 PDWH750* PDWH1000 *Model PDWH750 is no longer offered but is kept in this manual for reference purposes on previous equipment purchases.
  • Page 2 19th century. Today... advanced pulse technology has finally found and proven its way to the water heater industry. Fulton has brought pulse combustion applications out of the residential and light commercial application to larger commercial/industrial heating uses.
  • Page 3 Contents Safety Warnings Section and Precautions-3 Installation-7 Operation-25 Maintenance-33 Parts and Warranty-37 1-PDWH...
  • Page 4 2-PDWH...
  • Page 5 Section Safety Warnings and Precautions 3-PDWH...

  • Page 6: For Your Safety

    WARNING outlet, and the flue gas outlet pipes, Contact your Fulton Representative for vibration isolation packages designed HOTTER WATER CAN SCALD: Water heaters are intended to specifically for your application. Section 2.
  • Page 7 WARNING NOTE Do not use matches, candles, flame or other sources It is recommended that an authorized Fulton Pulse of ignition to check for gas leaks. Section 2. start up agent make any required gas input adjustments. Section 2. NOTE...
  • Page 8 The following are copies of safety labels and warnings which are affixed to the Fulton Pulse Water heaters. They are reproduced here as a further safety precaution and as a reminder to quickly identify them on the water heater. For Your Safety...
  • Page 9 Section Installation 7-PDWH...

  • Page 10: Installation

    In some cases the approval authority may Included with and insist that the installation conform to the packaged separately The Fulton Pulse water heater is an American Society of Mechanical Engineers automatic gas fired, direct vent water with each water heater ASME safety standard for controls and heater.
  • Page 11 Installation Figure 1 *Clearence from top of water heater to combustables must be no less than 12”. AIR INTAKE PIPING Number of 90 Degree Model No. Type Diameter/In. Length/Ft. Elbows PDWH750 10 Minimum 35 Maximum PDWH1000 10 Minimum 35 Maximum EXHAUST VENT PIPING Number of 90 Degree...

  • Page 12: Locating The Water Heater

    Failure to follow just touches the shim. The shim may Fulton supplies 4 elastomer coated this procedure could result in bent or now be removed. Proceed with fiberglass cubes used for vibration broken leveling bolts or springs, or adjustment of the other three isolators.
  • Page 13 Installation Installing Water Heater WARNING 6. Install expansion tank 7. Clearence from hot water pipes to Trim No shutoff of any kind shall be placed combustibles must be at least 6”. between the safety relief valve and the 1. Each water heater is supplied with a 8.
  • Page 14 Figure 3b utilized with any size pulse unit supplied compression fitting on the float. The by Fulton. The 3/4” condensate drain on A condensate collecting tank and water line must be connected to an the pulse unit will be connected to the 1”...

  • Page 15: Installing Gas Piping

    Installation Pipe Capacity For Natural Gas Nominal Equivalent Maximum Capacity in Cubic Feet of Natural Gas Per Hour Iron Pipe Internal Pipe Length Pressure Drop of 0.5" W.C. Size Diameter 90Þ Elbow Equivalent Length of Pipe in Feet Inches Inches Feet Feet 1.25...

  • Page 16: Electrical Schematic

    Installation Installing Field Wiring Figure 5 It is recommended that an independent power supply line be provided for the water heater. Connect one 120 volt (60Hz) fused powerline to terminal block as shown in Figure 5a. Connect applicable wires to neutral and ground. Connect a ground wire to green colored ground lug in electrical control box.
  • Page 17 Installation Figure 5b Sequence of Operation Glossary 6. 120V power is input to the automatic — Audible Alarm Control 1. Turn on main breaker. control relay (RM7865A). (Optional) 2. Low water safety relay (LWSR) is — Automatic Control Relay energized when the main breaker is 7.
  • Page 18 Installation Air Intake Supply Piping Air Intake Installation Preparation Schedule Water Heater 40 PVC Pipe Connection The water heater is equipped with air intake supply and exhaust vent Pipe-to-Tubing connections located at the top and rear Adapter of the water heater. Figure 6 Air supply is on the top.
  • Page 19 Do not mix stainless steel pipe with For muffler drain installation: galvanized or other alternatives for the NOTE: A Fulton PDWH water heater 1. For mufflers installed in the vertical entire length of the system. should not be connected to a common configuration the drain can be plugged.
  • Page 20 Installation air space clearances apply to indoor away from gas vent and out of the Air Intake Supply and or outdoor vents—whether they are required air space clearance. Exhaust Vent open, enclosed, horizontal or vertical Vertical runs or vent pipes and fittings Installation or pass through floors, walls, roofs, or passing through floors, ceilings, or in...

  • Page 21: Vertical Vent Termination

    Installation Figure 11 Figure 9 Figure 10 Elements For Correct Roof Fire Stopping Required For All Fire Stop Flashing Installation Ceiling/Floor Penetrations Nail through the upper portion and sides of the base flange. Use nail with neoprene washers or cover the nail heads with a neoprene plastic.
  • Page 22 Installation Horizontal Installation When penetrating a non-combustible Minimum wall thickness through which wall, the hole through the wall must be vent system may be installed is 3 ". Wall Penetrations large enough to maintain the pitch of the Maximum wall thickness through which vent and provide sealing.

  • Page 23: Wall Thimble Installation

    Installation Figure 14 Nominal Pipe & Thimble Diameters Pipe Size (in.) Ø Ø Ø 3" " " " 4" " " " 6" " Fixed " Pipe Size (cm) A Ø Ø Ø 7.62 17.46 13.81 8.41 10.16 23.81 21.59 10.63 15.24 20.64...
  • Page 24 Installation to vent these locations. When only water is refill/purge the system. If no pressure drop is discharged from all vents, the initial purging is detected for a period of two hours under complete. pressure, the system may be considered water tight.

  • Page 25: Installation Guidelines

    1000 must be configured so the Guidelines storage tank system or other custom temperature differential across the unit engineered solution is required. Fulton is should be no greater than 100 degrees not responsible for system designs that F. We recommend to those personnel...

  • Page 26: Installation Checkpoints

    Installation Installation Checkpoints 1. Before Starting The Water Heater: Do not turn on the water heater unless it is filled with water as shown by indicating light on panel box. 2. Check that the front door of the air decoupler box is closed. Door must be closed before starting the water heater.
  • Page 27 Make sure installation complies with It is recommended that an autho- operating properly. Cycle water heater all applicable codes. rized Fulton Pulse start up agent or several times by raising and lowering your gas utility make any required operating temperature on the thermostat.
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  • Page 29 Section Operation 26-PDWH...

  • Page 30: Operation

    Operation Post these instructions in an 1.Set the water temperature to Starting the Fulton Pulse desired setting. appropriate place near the Water Heater water heater and maintain in good legible condition. NOTE WARNING Prior to starting, make sure the proce-...

  • Page 31: Sequence Of Operation

    Operation Causes for hold conditions in the INITIATE sequence are: Check for possible restrictions (foreign • AC line dropout is detected. objects, snow, rags, leaves, etc.) in • AC line frequency error caused by either the air supply inlet or the exhaust using a 60 Hz device on a 50 Hz line or outlet on the outside of the building.
  • Page 32 Operation IGNITION TRIALS After the CPSP/MFSP, the RM7865 will (Without Flame Rod Option) enter into the RUN sequence. The a. Combustion Pressure Establishing RM7865 will remain in RUN until the Period (CPEP): controller input, terminal 6, opens 1. The ignition transformer, terminal 10, indicating that the demand is satisfied or is energized two seconds prior to that the limit has opened.

  • Page 33: Advanced Programming Features

    1. When the water heater receives a call Bold & Italic values in the menu pertain customer values handy for trouble for heat, the prepurge cycle is initiated. to the program constructed for Fulton shooting. pulse water heaters. 2. The mod motor is driven to high fire.
  • Page 34 Operation Worksheets for Yokogawa UT320/UT350 Temperature Control Program for Pulse Modulating Water Heaters Input/Output Menu SYMBOL DESCRIPTION DEFAULT VALUE FULTON VALUE CUSTOMER VALUE Input Type UNIT Input Unit Selection Range High variable Range Low variable Scale Decimal Point Scale High...
  • Page 35 Operation Operating Parameters SYMBOL DESCRIPTION DEFAULT VALUE FULTON VALUE CUSTOMER VALUE Alarm 1 Setting Alarm 2 Setting Alarm 3 Setting Auto-Tune Super Function On/Off SP.no Target Setpoint PID Parameter Enter 1 for PID Menu then 0 PV Input Filter PV Input Bias eus (0.0%)
  • Page 36 Operation Linkage - The longer the radius on the exhaust 1) Turn water heater OFF. valve pivot arm, the slower the exhaust Adjustment for butterfly valve shuts off. Conversely, 2) Put the temperature control in manual the shorter the radius the quicker the mode (press the A/M key once –...
  • Page 37 Section Maintenance 34-PDWH...

  • Page 38: Maintenance

    NOTE Recommended Monthly Recommended Annual Maintenance Maintenance Your Fulton Pulse water heater has been designed for years of trouble-free Inspect the air intake and exhaust vent 1. Change the spark plug. performance. To ensure the continued pipes for broken seals at the joints.

  • Page 39: Troubleshooting

    Troubleshooting 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...
  • Page 40 Maintenance Troubleshooting--Fault Code Diagnosis Fault Code System Failure Recommended Troubleshooting Fault 02 Excess noise or device running on 1. Check the relay module and display module connections. *AC Frequen/Noise* slow AC. 2. Reset and sequence the 7800. 3. Check the 7800 power supply to assure that both frequency and voltage meet specifications.
  • Page 41 Section Parts and Warranty 38-PDWH...
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  • Page 43 Replacement Parts (available from authorized Fulton Representatives) Models PDWH Part Number Description 1000 2-30-000232 Air switch-purge fan 2-30-001334 Air switch-proof of flame 2-12-000551 Air flapper gaskets Air Flapper Spacers and Valve Assemblies* 7-37-000124 Air flapper valve assy w/o housing 7-37-000123...

  • Page 44: Replacement Parts

    4” PVC term. w/screen 45 deg. elbow 4-57-000170 4” PVC term. w/screen-90 deg. elbow *Air flapper spacers, air flapper valve assemblies, and gas orifices must be requested by contacting your authorized Fulton representative. Please advise serial number on purchase order or quote request. 40-PDWH...
  • Page 45 3” x 18” adjustable-7324GC 2-35-000998 3” horizontal termination-7390GC 2-35-000996 3” horizontal support-7323GC 2-60-000114 Hi temp. sealant-10 oz. 2-Misc 7000RTV Sealant-5 oz. 2-Misc 7000RTVL Sealant-10 oz. *Contact Fulton for 6” venting material Any venting material must be listed by a recognized testing agency 41-PDWH...
  • Page 46 - PAGE INTENTIONALLY LEFT BLANK - 42-PDWH...

  • Page 47: Warranty

    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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  • Page 50 Fulton Heating Solutions, Inc. For more of the following patents apply to this unit: U.S. Patent Numbers 4856558, 4884963, 4926789, 4951706 and 5, 145, 345.

This manual is also suitable for:

Pdwh1000

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