FULTON FHE-250 Instruction manual

FHE-250 MANUAL 09 2014 ISSUE 2
Fulton Ltd
FHE-250 Gas Fired
Condensing Boiler
250 kW
This Manual must be available to the boiler operator at all times.
INSTALLATION, OPERATION & MAINTENANCE
MANUAL

FHE-250 MANUAL 09 2014 ISSUE 2
The Pressure System Safety Regulations 2000
Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a ‘Competent Person’.
The scope of the examination and the actual intervals between examinations is at the discretion of the
competent person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the
system in which a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do
not cover periodic statutory inspections.
For further information contact:-
(a) SAFed
SAFETY ASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.
(b) Health and Safety Executive local ofce.
(c) Your Competent Person.
For your Safety!
The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
WARNINGS must be observed to prevent
serious injury or death to personnel.
CAUTIONS must be observed to prevent
damage or destruction of equipment or loss of
operating effectiveness.
NOTES: must be observed for essential and
effective operating procedures, conditions and
as a statement to be highlighted.
It is the responsibility and duty of all personnel
involved in the operation and maintenance of this
equipment to fully understand the WARNINGS,
CAUTIONS and NOTES by which hazards are to be
eliminated or reduced.
Personnel must become familiar with all aspects of
safety and equipment prior to operation or
maintenance of the equipment.
WARNING
Hot Water Boilers are a potential hazard, possibly fatal if not properly
maintained.
CAUTION
It is vitally important that the instructions
given in this manual are strictly adhered to.
Failure to carry out the routine maintenance
checks could result in a drastic reduction in the
life expectancy of the boiler.
CAUTION
Incase of Emergency
This boiler has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.
If such a condition should occur during commissioning or during subsequent operation of this product, what so
ever the cause, then the fuel supply to the boiler should be isolated immediately, until such time that the fault
has been investigated by a competent person and rectied.
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FHE-250 MANUAL 09 2014 ISSUE 2
LIST OF CONTENTS
INTRODUCTION 1
General 1.1
Technical Data 1.2
Optional Extras 1.3
Safety 1.4
- Safe Handling 1.4.1
- Safe Handling of Substances 1.4.2
INSTALLATION 2
General 2.1
Siting 2.2
Water Circulation System 2.3
Water Piping Installation 2.4
Water Treatment 2.5
Frost Protection 2.6
Preventing Oxygen Contamination 2.7
Eliminating System Air 2.8
Filling the Boiler with Water 2.9
Gas Supply 2.10
- Gas Connection 2.10.1
Sealed System Requirements 2.11
Ventilation 2.12
- Common Air Intake and Exhaust Venting of
Multiple Boilers
2.12.1
- Intake Duct Sizing 2.12.2
Exhaust Venting Terminations (Flues) 2.13
- Horizontal Exhaust Vent Termination 2.13.1
Flue Installation 2.14
- Flue System Design 2.14.1
- Flue Gas Conditions 2.14.2
Condensate Drain 2.15
Water and Gas Header Installation (Optional Extra) 2.16
Electrical Supply 2.17
Hydraulic Resistance 2.18
Electrical Connections 2.19
- External Wiring 2.19.1
- Terminal Connections for External Wiring 2.19.2
OPERATION 3
General 3.1
Perform Pre-Start-Up Inspection 3.2
Fill and Purge the System 3.3
Commissioning the Boiler 3.4
- Electrical Installation 3.4.1
- Gas Installation 3.4.2
- Flue Commissioning 3.4.3
Test of Ignition Safety System 3.5
Perform Test of Low Gas Pressure Switch 3.6
Test of Condensate Pressure Switch 3.7
Normal Operation of the Boiler 3.8
- Boiler Test Fire 3.8.1
- Disabling the Boiler 3.8.2
- Changing the Temperature Setpoint for DHW 3.8.3
- Changing the Temperature Setpoint for CH 3.8.4
- Finding the Master Boiler 3.8.5
- Boiler Operation 3.8.6
- Auto Detection 3.8.7
Shutdown Procedures 3.9
- Normal Shut off Procedures 3.9.1
- Emergency Shut off Procedures 3.9.2
- Shutting the Boiler Down for an Extended Period
of Time
3.9.3
- Starting the Boiler after Prolonged Shutdown 3.9.4
Display Operation 3.10
Symbols on the LCD 3.11
Push-buttons 3.12
Backlight 3.13
User Interface Operating Modes 3.14
- Initial Mode 3.14.1
- Standby Mode on Master DSP 3.14.2
- Standby Mode on Slave DSP 3.14.3
- Suspend Mode 3.14.4
- CH Setpoint Adjust Mode 3.14.5
- Auto Detection Mode 3.14.6
- Cascade Test Mode 3.14.7
- Local Test Mode 3.14.8
- Local Installer Mode 3.14.9
- History Mode 3.14.10
- Installer+ Mode 3.14.11
MAINTENANCE 4
General 4.1
Safety 4.2
Partial Isolation of Boilers in Cascade Systems 4.3
Servicing Schedule 4.4
- Daily 4.4.1
- Weekly 4.4.2
- Monthly 4.4.3
- Annual 4.4.4
Procedure for Cleaning the Air Inlet Filter 4.5
Examine the Flue System 4.6
Inspect Heating System for Other Problems 4.7
Procedure for Removing/Cleaning the Burner 4.8
Procedure for Cleaning the Heat Exchanger 4.9
Gas Valve Adjustment 4.10
After All Repairs and Maintenance 4.11
Handing Over 4.12
Error Codes and Troubleshooting 4.13
Maintenance Log 4.14
GENERAL DATA 5
Boiler Dimensions 5.1
Boiler Specication 5.2
Seasonal Efciencies 5.3
Recommended Water Conditions 5.4
Name Plates and Packaging Label 5.5
Electrical Diagrams (Supplied Separately)

FHE-250 MANUAL 09 2014 ISSUE 2
LIST OF CONTENTS
WARNING
Do not try to do repairs or any other maintenance work you
do not understand. Obtain a Service Manual from Fulton or
call a Fulton Service Engineer.
WARNING
It is the responsibility of the installer to ensure all parts
supplied with the boiler are tted in a correct and safe
manner.
WARNING
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and or damage.
WARNING
A defective boiler can injure you or others. Do not operate
a boiler which is defective or has missing parts. Make sure
that all maintenance procedures are completed before using
the boiler.
CAUTION
Obey all laws and local regulations which affect you and
your boiler.
WARNING
Do not change the boiler fuel without consulting the boiler
manufacturer.
WARNING
LIFTING EQUIPMENT
Make sure that lifting equipment complies with all local
regulations and is suitable for the job. You can be injured
if you use faulty lifting equipment. Make sure the lifting
equipment is in good condition.
WARNING
Operating the boiler beyond its design limits can damage
the boiler, it can also be dangerous.
Do not operate the boiler outside its limits.
Do not try to upgrade the boiler performance by unapproved
modications.
WARNING
Non-approved modications can cause injury and damage.
Contact your Fulton dealer before modifying the boiler.
WARNING
Only qualied persons should be allowed to operate and
maintain the boiler and its equipment. Boilers should always
be drained through an approved Blowdown Vessel.
WARNING
The installation of Gas appliances including the ue system
should only be carried out by Gas Safe Registered
Engineers.
CAUTION
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and is
normally only required by engineering
surveyors / inspectors.
In order to ensure the material / pressure vessel does not
suffer from brittle fracture, hydraulic testing should not be
carried out below 7°C.
WARNING
DANGER FROM HOT SURFACES
Hot Water Boilers have high temperature surfaces, that if
touched may cause serious burns. Only competent and
qualied personnel should work on or in the locality of a
steam boiler and ancillary equipment. Always ensure the
working area and oor are clear of potential hazards, work
slowly and methodically.
Do NOT store inammable materials near the boiler.
WARNING
DANGER FROM INCOMPLETE COMBUSTION
The importance of correct burner adjustment to achieve low
emissions, safe, clean and efcient combustion is
paramount. Poor combustion, where unburnt gas forms
carbon monoxide is both a health hazard, and the potential
risk to the boiler from overheating, caused by re-burning of
the un-burnt gas in the secondary ue passes.
WARNING
The importance of correct boiler water and feedwater
cannot be over emphasised, see the relevant section in this
manual.
CAUTION
LOW FEEDWATER TEMPERATURE
Low feedwater temperature can result in thermal shock to
the boiler pressure vessel. Return the maximum amount of
condensate and if necessary pre-heat the feedwater. If in
doubt consult Fulton Ltd.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and
chemical treatment plants CAN BE SUPPLIED by Fulton.
It is the responsibility of the operator to ensure adequate
supplies of chemical are available at all times (including
commissioning).Costly repairs could be required should
the plant operate without chemicals or the wrong dosage of
chemicals.
SAFETY
The instructions provided for the operation and maintenance of the boiler MUST be observed.
Failure to do so could result in damage to the boiler and serious personal injury.
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FHE-250 MANUAL 09 2014 ISSUE 2
TITLE FIG. NO.
General Arrangement 1
General Arrangement with Panels Removed 2
Typical Gas Train 3
Flue Gas Conditions 4
Boiler Hydraulic Resistance 5
Boiler Communication Cables 6
Electrical Terminals 3-13 Disconnected 7
Jumper 8
Inserted Jumper Between Terminals 19 and 20 9
LCD Glass Layout 10
Push-button Layout 11
Boiler Dimensions 12
Name Plates 13
LIST OF ILLUSTRATIONS

FHE-250 MANUAL 09 2014 ISSUE 2
FIG.1 GENERAL ARRANGEMENT
Boiler Control
Panel
Adjustable Feet

FHE-250 MANUAL 09 2014 ISSUE 2
Page 1
1
The boilers are fully automatically controlled, oor standing and efcient condensing appliances.
The FHE-250 comprises of a single module capable of delivering 250 kW.
Up to 12 FHE-250 modules can be cascaded (for simplicity, only 250-1000 kW models are shown in
this manual), being stacked either vertically or horizontally.
The boiler controls built into the appliance include:
• Volt free ‘alarm’ contacts
• Burner hours run meters
• System temperature indication
The boilers can draw combustion air from the room or via ducting from outside.
Each module provides a maximum of 250 kW heat output and will modulate down to 41.66 kW
(see the table in Section 5.2 - Boiler Specication, for efciencies at different temperatures).
Boilers comprising of more than one module will share the heating load equally among modules,
switching modules off individually once the heating load drops below 16.67% of the total boiler
capacity. This way, a decreasing load is continuously matched for optimum efciency. The minimum
output from all models is 41.66 kW, providing a turndown ration of 6:1 for the 250 kW, 12:1 for the
500 kW, 18:1 for the 750 kW and 24:1 for the 1000 kW. Modules will re on the basis of least hours
run under the dictates of lead/lag sequencing from the onboard controller.
Each module includes a ap which only opens when the fan is running. This prevents energy wastage
when the boiler module is not ring.
The boilers are capable of high operating efciencies and low emissions (see Section 5) through
the combination of a sophisticated control system with premix burner and a stainless steel heat
exchanger.
These boilers are certied to meet the requirements of the EC Gas Appliance Directive, Boiler
Efciency Directive, EMC and Low Voltage Directive.
CAUTION
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners and chemical
treatment equipment CAN BE SUPPLIED by Fulton. It is the responsibility
of the operator to ensure adequate supplies of chemical are available at all times
(including commissioning). Costly repairs could be required should the plant operate
without chemicals or the wrong dosage of chemicals.
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SECTION 1 - INTRODUCTION
1.1 GENERAL
1.2 TECHNICAL DATA
For a full specication refer to Section 5.2 - Boiler Specication.

FHE-250 MANUAL 09 2014 ISSUE 2
Page 2
1
yAir Inlet Ducting Kit
For FHE-500 and above:
yWater and Gas Header Assembly - Packaged
yWater and Gas Header Assembly c/w Valves - Packaged
yFlue Header Kit
Note: Please contact Fulton Ltd for further details of all optional extras.
1.3 OPTIONAL EXTRAS
1.4 SAFETY
Current Gas Safety (Installation and Use) Regulations or rules in force.
The appliance is suitable for installation in any EU country and should be installed in accordance with
the rules in force.
In the UK, the installation must be carried out by a Gas Safe Registered Engineer or in IE by a
competent person. It must be carried out in accordance with the relevant requirements of the:
yGas Safety (Installation and Use) Regulations
yThe appropriate Building Regulations either The Building Regulations, The Building Regulations
(Scotland), Building Regulations (Northern Ireland).
yThe Water Fittings Regulations or Water by-laws in Scotland.
yThe Current I.E.E. Wiring Regulations.
Where no specic instructions are given, reference should be made to the relevant British Standard
Code of Practice.
In IE, the installation must be carried out by a Competent Person and installed in accordance with the
current edition of I.S.820:2000 “Non Domestic Gas Installations”, the current Building Regulations
and reference should be made to the current ETCI rules for electrical installation.
The boilers have been tested by a notied body and conform to EN656 and EN15417 for use with
Natural Gas. Detailed recommendations are contained in the following Standards and Codes of
Practice:
BS. 5854 Flue and ue Structures in Buildings.
BS. 6644 Installation of gas red hot water boilers of rated inputs between 70 kW and
1.8 MW (net) (2nd and 3rd family gases).
BS. 6880 Low temperature hot water heating systems of output greater than 45 kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
IGE/UP/1 Soundness testing and purging of industrial and commercial gas installations.
IGE/UP/2 Gas installation pipework, boosters and compressors on industrial and
commercial premises.
IGE/UP/10 Installation of gas appliances in industrial and commercial premises.

FHE-250 MANUAL 09 2014 ISSUE 2
Page 3
1
The FHE-250 may require 2 or more operatives to move it to its installation site, and when moving
into its installation location. Manoeuvring the boiler will include the use of a pallet truck or forklift and
may involve pushing and pulling.
Caution should be exercised during these operations.
Operatives should be physically capable, and knowledgeable in handling techniques, when
performing these tasks. The following precautions should be reinforced:
yBe physically capable.
yUse personal protective equipment as appropriate, e.g. gloves, safety footwear.
During all manoeuvres, every attempt should be made to ensure the following:
yKeep back straight.
yAvoid twisting at the waist.
yAvoid upper body/top heavy bending.
yAlways grip with the palm of the hand.
yUse designated hand holds.
yKeep load as close to the body as possible.
yAlways use assistance if required.
1.4.1 SAFE HANDLING
1.4.2 SAFE HANDLING OF SUBSTANCES
No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture.

FHE-250 MANUAL 09 2014 ISSUE 2
Page 4
FIG. 2 GENERAL ARRANGEMENT WITH PANELS REMOVED
Venturi
Fan
Electrical Plate
Heat Exchanger
Return Pipe
Flow Pipe
Gas
Valve
Condensate
Pipe
Automatic
Air Vent