FULTON PHW 1000 Installation, Operation And Maintenance Manual Download Page 1

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Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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Fulton PulseHW

Gas Pulse Combustion

Hydronic Heating Boilers

Installation, Operation and Maintenance Manual

Fulton Heating Solutions, Inc.

972 Centerville Road
Pulaski, NY 13142
Telephone: (315) 298-5121
Facsimile: (315) 298-6390

www.fulton.com

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Summary of Contents for PHW 1000

Page 1: ...nance Manual Fulton Heating Solutions Inc 972 Centerville Road Pulaski NY 13142 Telephone 315 298 5121 Facsimile 315 298 6390 www fulton com Serial __________________________ Model ___________________...

Page 2: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 2...

Page 3: ...ntake Exhaust Piping Requirements for the Pulse Boiler 22 Air Intake Supply and Exhaust Vent Installation 23 Vertical Vent Flashing and Installation 24 Vertical Vent Termination 25 Horizontal Installa...

Page 4: ...tion 4 Maintenance 1 Before Each Heating Session 2 Recommended Monthly Maintenance 3 Recommended Annual Maintenance 4 Troubleshooting 5 Troubleshooting Fault Code Diagnosis 6 Troubleshooting RM7865C w...

Page 5: ...e design compensates for expansion and contraction which cause other boilers to eventually leak or fail No Expensive Chimney Needed Pulse combustion is self venting through an AL29 4C stainless steel...

Page 6: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 6...

Page 7: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 7 Section 1...

Page 8: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 8...

Page 9: ...ME welding inspection d ASME hydrostatic test inspection e Electrical components inspection f Operating test g Final engineering inspection h Crating inspection All units are crated for forklift trans...

Page 10: ...rty damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliances WHAT TO DO IF YOU SMELL GAS Do not try to...

Page 11: ...nition system components are protected from water dripping spraying rain etc during boiler operation and service Note All pulse combustion boilers must be installed with vibration isolators No pulse c...

Page 12: ...ndling units where they may be exposed to refrigerated air circulation such boiler piping systems shall be equipped with flow control valves or other automatic means to prevent gravity circulation of...

Page 13: ...ir tight and will not allow contaminates from the boiler room into the boiler The cement shall be free flowing and contain no lumps undissolved particles or any foreign matter that adversely affects t...

Page 14: ...call a qualified service technician to inspect the boiler and to replace any part of the control system and or gas control s which has been under water Note Prior to starting make sure the procedure...

Page 15: ...ars 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 ann...

Page 16: ...713 Page 16 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 re...

Page 17: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 17 Section 2...

Page 18: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 18...

Page 19: ...oiler Height 64 IN 64 IN 76 IN 76 IN 81 IN 81 IN Boiler Depth 37 8 IN 37 8 IN 50 8 IN 50 8 IN 65 IN 75 8 IN 2 Introduction a The Fulton Pulse combustion hydronic boiler is an automatic gas fired direc...

Page 20: ...e following items are standard trim for Fulton Pulse Combustion Hydronic Boilers a Fully Insulated b Microprocessor Based Control 120 volt c Low Water Cutoff Probe Type d Control Panel Completely Wire...

Page 21: ...y that all minimum clearances as per factory requirements in Figure 1 below are observed as well as any local codes that pertain to the geographic location where the boiler is being installed Note The...

Page 22: ...r with jacks or similar tools Do not attempt to raise the boiler via one 1 lifting point but lift evenly around the perimeter of the boiler Slide the spring isolator under the boiler or mounting brack...

Page 23: ...im next to each bracket between the boiler and the housekeeping pad or structural floor If an operating clearance of other than one inch is desired use an appropriate size shim e Raise the boiler and...

Page 24: ...igure 3a The safety relief valve must be installed with a 6 nipple 8 for PHW2000 between the boiler and the safety valve The safety relief valve must always be installed in the vertical position The d...

Page 25: ...th a pressure temperature gauge A nipple is installed in the boiler water outlet A tee is installed on the nipple In the side port of the tee the pressure temperature gauge is installed 11 Installing...

Page 26: ...fferential across the heat exchanger is 170 degrees F Minimum outlet temperature for carbon steel units must be 120 degrees F or greater Maximum allowable outlet temperature is 240 degrees F 3 For boi...

Page 27: ...e 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 d...

Page 28: ...3 Install the condensate piping to the condensate drain in the lower right hand side of the boiler 4 Connect 3 4 condensate drain s to the 1 header connected in a manifold as shown in Figure 3b The he...

Page 29: ...natural gas Pipe Capacity for Natural Gas Nominal Iron Pipe Size Internal Diameter Equivalent Pipe Length 90 o Elbow Tee Maximum Capacity in Cubic Feet of Natural Gas Per Hour Pressure Drop of 0 5 W...

Page 30: ...ff valve from the gas supply piping system during any pressure testing of the system at pressure in excess of 1 2 psig 14 WC 3 5 kPa g The boiler must be isolated from the gas supply piping system by...

Page 31: ...x Note The boiler shall be installed such that the gas ignition system components are protected from water dripping spraying rain etc during boiler operation and service Warning Do not attempt to star...

Page 32: ...d The Temperature Control allows current to pass to the High Temperature Control Circuit if the temperature control senses a Call for Heat e High limit temperature control allows current to pass to th...

Page 33: ...S Low Water Test Switch GV1 2 Main Gas Valve PL Panel Light Power on Green SG Spark Generator S P Spark Plug CFH Panel Light Call for Heat FF Panel Light Flame Failure FP Flame Programmer CSR Condensa...

Page 34: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 34 Typical PHW 2000 Electrical Drawing with Optional ModSync...

Page 35: ...Model No Type Base Diameter In Length Ft Number of 90o Elbows PHW300 Stainless Steel 4 4 10 Minimum 35 Maximum 0 4 PHW500 Stainless Steel 4 4 10 Minimum 35 Maximum 0 4 PHW750 Stainless Steel 4 4 10 Mi...

Page 36: ...pipe All Schedule 40 PVC pipe fittings primer and cement must conform with American National Standard Institute and the American Society for Testing and Materials ANSI ASTM standards d For applicatio...

Page 37: ...55 should be adhered to 1 Measure and cut PVC pipe to desired Iength 2 Chamfer end of pipe removing any ridges or rough edges If end is not chamfered the edge of the pipe may remove cement from the fi...

Page 38: ...cement from pipe at end of fitting socket A properly made joint will show a bead around its entire perimeter Any gaps may indicate a defective assembly due to insufficient cement 9 Handle joints caref...

Page 39: ...c Consult factory for assistance d All common venting arrangements must result in a pressure drop of 0 1 to 0 0 w c if not using a draft assist fan Consult factory for assistance e All common venting...

Page 40: ...between the boiler and the condensate drain For best noise attenuation the muffler should be installed as close to the boiler as possible 21 Air Intake Exhaust Piping Requirements for the Pulse Boiler...

Page 41: ...and ceilings The fire stop must close in the area between the outside of the vent and the opening in the structure Figure 9 When passing through a floor or ceiling frame provide an opening 5 to 9 air...

Page 42: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 42 Figure 8...

Page 43: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 43 Figure 9 Figure 10 Figure 11...

Page 44: ...ge with roofing material 24 Vertical Vent Termination a The vent pipe must extend through the flashing to a height above the roof as required in Figure 12 A storm collar is installed on the vent pipe...

Page 45: ...he hole through the wall must be large enough to maintain the pitch of the vent and provide sealing Use adhesive material to seal around the vent on both sides of the wall When penetrating a combustib...

Page 46: ...and vent pipes from being pushed or pulled b Insure wall thimble for exhaust vent contains internal insulation prior to installation 27 Horizontal Vent Termination a The vent termination is joined to...

Page 47: ...ll and purge the heating system using the following sample procedure Note The following purge procedure is applicable to the piping configuration as shown in Figure 15 1 Close combination shutoff purg...

Page 48: ...rom the vent Close the vent and make sure it s watertight Repeat procedure for all high points and for every zone Warning Never leave an opened manual air vent unattended In the event an opened vent i...

Page 49: ...gas to flow to boiler 29 Installation Checkpoints a Before Starting The Boiler Do not turn on the boiler unless it is filled with water as shown by indicating light on panel box b Check that the fron...

Page 50: ...low Rate a Turn off the boiler and close the manual gas shutoff valve Remove manifold downstream pressure test plug from the 90 degree elbow b Replace the plug with a 1 4 N P T to 1 4 compression or f...

Page 51: ...tricting bleed valve shall not be used 33 Rating the Boiler a After the boiler has been operating for about 15 minutes check gas input rate to be sure boiler is operating at design capacity 34 To Chec...

Page 52: ...e in two steps i Reduce the pressure to 5 psig ii Reduce the pressure from 5 psig to 14 WC 3 The preferred regulator for this application is the Fisher S202 with a stabilizing booster cartridge SBC 4...

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Page 55: ...not use any phone in your building Immediately call your gas supplier from a neighbor s phone and then follow your gas supplier s instructions If you cannot reach your gas supplier call the fire depa...

Page 56: ...the boiler c Set temperature control to desired setpoint d Turn operating switch on boiler to ON position The boiler is energized and 35 second prepurge begins After 35 seconds the spark ignitor and...

Page 57: ...on threads of plug g When the unit fires and pressure is sensed in air valve housing the unit will continue to operate until main power is shut off to the controller either through the temperature sw...

Page 58: ...plier 1 Turn off all electric power to the boiler if service is required 2 Turn gas cock knob clockwise to OFF 4 Sequence of Operation a INITIATE The RM7865 enters the five second INITIATE sequence wh...

Page 59: ...start the PREPURGE sequence 3 The purge fan switch ILK input must close within three seconds to start the 35 second PRE PURGE otherwise lockout occurs f IGNITION TRIALS without Flame Rod Option 1 Comb...

Page 60: ...ing this time the RM7865 will recycle to PREPURGE if the selected number of entry attempts is not exceeded If the retry attempts exceed the limit lockout occurs h RUN After the CPSP MFSP the RM7865 wi...

Page 61: ...erator mode PV display will show oppa b Press Down Arrow key until control is in Set Up mode PV display will show stup c Press SET ENT key twice until control is in Function mode PV display will show...

Page 62: ...n When the PID parameter appears in the PV Display press one of the Arrow keys until 1 appears in the SP Display press SET ENT this will take you to a subset of parameters Repeat Parameter Setting Pr...

Page 63: ...S3 Custom Select Off Off C S4 Custom Select Off Off LOCK Key Lock Off Off PWD Password 0 0 Note Parameters with bold values only will be used Functional Parameters Symbol Description Default Value Fu...

Page 64: ...Off Off HB2 Heater Disconnect Off Off HC1 Heater Disconnect Off Off HC2 Heater Disconnect Off Off ORB On Off Rate Detection eus 1 0 0 ORH On Off Rate Upper Limit 100 100 ORL On Off Rate Lower Limit 0...

Page 65: ...below setpoint 4 The control will increase the mod motor again to 100 until the process temperature is 2 of input span above setpoint During this time the manual mode light on the temperature control...

Page 66: ...ecimal place unit signal for out of range 0010 0121 SCL Range start analog input 1 c 0 0 SCH Range end analog input 1 c 100 210 stainless steel 250 carbon steel SCL2 Range start analog input 2 c 0 0 S...

Page 67: ...ature Actual outdoor temperature SP E Pre definition of external setpoint 1 Linkage Adjustment for Pulse Modulated Boilers a This instruction covers the adjustment of the linkage arms and rods between...

Page 68: ...begin or finish travel in the vertical position If this occurs there is a possibility that the gears will bind and cause damage to the mod motor 4 The gas pressure regulator is the only means for adju...

Page 69: ...the temperature control must be disconnected Install a jumper from 17 to contact point on the mod motor This will provide a direct connection between and on the temperature control to and on the mod m...

Page 70: ...g Solutions Inc PHW Manual 2010 0713 Page 70 j 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...

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Page 73: ...the boiler running check for visible cracks at fittings and joints Warning Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids 2 Recommended Mont...

Page 74: ...that the boilers flue passage ways have become blocked contact your recognized Fulton representative Note On models PHW300 through PHW1400 the spark plug is located in the top of the boiler In PHW200...

Page 75: ...ould be contacted Problem Cause Check Starting or Purge Failure Power Supply Check fuse or circuit breaker Reset or replace as necessary On Off Switch For all models check to see if on off switch is i...

Page 76: ...er gab 050 060 for Champion spark plug Clean or replace as necessary Loose Wire Connection Check connections to all components Temperature Control Check that the operating temperature control is set h...

Page 77: ...nents Air Flappers Check to see if the flappers on the air valve plate are placed correctly covering the holes Gas Flappers Check to see if the flappers on the gas valve plate are placed correctly cov...

Page 78: ...low interlock fault 1 Check wiring correct any errors 2 Inspect the fan assure that there is no blockage of the air intake and that it is supplying air 3 Assure that the Airflow Interlock switches are...

Page 79: ...If fault persists replace 7865 flame programmer Fault 105 127 Call Service 1 Replace 7865 controller 6 Troubleshooting RM7865C without display a When the control has faulted out you can identify the f...

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Page 81: ...Fulton Heating Solutions Inc PHW Manual 2010 0713 Page 81 Section 5...

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Page 83: ...ir flapper metering plate assy x 3 8 7 37 000150 Air flapper metering plate assy x 3 8 7 37 000124 Air flapper metering plate assy x 3 8 7 37 000123 Air flapper metering plate assy x 3 8 7 37 000125 A...

Page 84: ...6 Gas decoupler x x 32 9 7 57 000125 Gas decoupler x x x 32 9 2 20 000204 Gas orifice 3 4 x 312 LP 0 12 2 20 000130 Gas orifice 3 4 x 437 LP 0 12 2 20 000209 Gas orifice 3 4 x 460 0 12 2 20 000208 Gas...

Page 85: ...mmer x x x x x x 2 2 40 000268 R7847A1041 AMP x 0 5 2 40 000270 Base for RM7865 x x x x x x 0 5 2 40 000272 Display module for 7865 x x x x x x 0 5 2 30 000120 Safety Valve 3 4 30 10 614 05 x x x x 2...

Page 86: ...n x x x x x 0 5 2 40 000423 Base for LWCO relay x x x x x x 0 25 2 12 000090 Retainer spring for LWCO relay x x x x x x 0 01 2 40 000418 MM750 P M T 120 LWCO Test Reset 3 2 40 000419 MM LWCO mr PS851M...

Page 87: ...861 2 x 14 flex cont water x x x x 2 58 2 35 000862 2 1 2 x 16 flex cont x 4 2 30 000550 4 x 16 flex cont water flanged x 9 2 35 000531 1 gas flex cont x x x 1 76 2 35 000532 1 1 4 gas flex cont x 2 7...

Page 88: ...temp sealant 10oz x x x x x x 8 00 000101 Material Handling Tool x 2 12 001020 Air decoupler insulation set foil faced x x 2 12 001021 Air decoupler insulation set foil faced x x 2 12 001022 Air deco...

Page 89: ...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 operated and maintained by the buy...

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Page 91: ...ment 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 operated and maintained by th...

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Page 94: ...manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies Fulton Boiler Works Inc Fulton Heating Solutions Inc Fulton Thermal Corporation are part o...

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