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.
!
!
!
!
!

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.
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!
!

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.
!
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

FHE-250 MANUAL 09 2014 ISSUE 2
Page 5
2
The installation of the FHE-250 Hot Water Boiler should be carried out by competent personnel in
accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that
these regulations are complied with.
WARNING
Maintenance on the burner assembly requires that the area directly in front of the boiler must
not be obstructed with pipework or equipment which would interfere with the removal of
the complete burner unit. Care should be taken on installation of the boiler to ensure this area
remains clear of obstructions.
!
WARNING
Do not allow weight to bear on equipment components to prevent damage.
!
SECTION 2 - INSTALLATION
2.1 GENERAL
2.2 SITING
(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1
Communication 1676, and in particular to Section 5, Location of Appliances).
The boiler house should be sufciently large to allow easy and safe access to all parts of the boiler
for operational and maintenance purposes.
1. The boiler must stand on a oor which must be at, non-combustible, level and of a suitable
load bearing capacity to support the weight of the boiler (when lled with water) and any
ancillary equipment.
2. The boiler must not be tted outside.
3. Install so that all system components are protected from water (dripping, spraying, rain etc)
during boiler operation and service.
4. Minimum clearance for access should be maintained at 600 mm at the front and at least one
side of the boiler/modular installation.
5. Ensure all labels on the boiler will be fully visible for maintenance and inspection.

FHE-250 MANUAL 09 2014 ISSUE 2
Page 6
2
A circulation pump MUST be connected to the boiler.
The boiler may be used for indirect hot water supply: wherever it is used for this type of system, an
additional heat exchanger must be provided to ensure hydraulic separation between primary and
secondary circuits.
Each boiler installation should incorporate a safety valve to ensure maximum pressure is not
exceeded.
The appliances are NOT suitable for gravity central heating nor gravity domestic hot water as system
pressure must be a minimum of 1 bar.
The boiler MUST be vented, there is an internal automatic air vent included for this purpose.
Draining taps MUST be located in accessible positions, which allow the draining of the whole
system - including the boiler and hot water storage vessel. They should be at least 1/2” BSP nominal
size and be in accordance with BS. 2879.
The central heating system should comply with the relevant standards on page 2.
Due to the compact nature of the boiler, the heat stored within the heat exchanger at the point of
shutdown of the burner must be dissipated into the water circuit in order to avoid overheating. To
allow pump operation after burner shutdown, the boiler control incorporates a pump overrun facility.
In order to make use of this, a pump must be controlled via the terminals inside the boiler.
When sizing pumps, reference should be made to hydraulic resistances given in Section 2.18, which
shows the boiler resistance against ow rates, to achieve the required temperature differential.
Flow rate using a 20°C temperature differential is 3.0 l/s (10.7 m³/hr) for each FHE-250
boiler/module.
The boilers MUST be installed in a closed loop system, it is the installers responsibility to ensure
adequate sized pressurisation units and expansion vessels are included for the system.
Note: With the boiler ring at maximum rate, the temperature differential should not be less than 20°C.
With the boiler ring at minimum rate, the temperature differential should not be greater than 35°C. Lower ow
rates generating higher temperature differentials will lead to poor system performance.
The lower the return temperature to the boiler, the higher the efciency. At return temperatures of 55°C and below,
the difference becomes marked because the water in the ue gases starts to condense, releasing its latent heat.
System designs should ensure the boiler minimum ow rates, as detailed in Section 5.2 - Boiler Specication,
are always maintained.
WARNING
If the water supply must be disconnected, the boilers must be turned off to prevent
accidental ue gas emission into the boiler room.
!
2.3 WATER CIRCULATION SYSTEM

FHE-250 MANUAL 09 2014 ISSUE 2
Page 7
2
All water supplies contain some solids, dissolved gases or dissolved minerals. These may encourage
corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting boiler
performance, valve operation and general pipe longevity, each location must be analysed and treated
accordingly.
Adhere to the following for water piping installation.
1. The boiler requires a minimum temperature differential across the heat exchanger at high re,
and has a minimum ow requirement.
2. Ensure piping arrangements allow for heat-up times at or below 30 seconds; this will reduce
condensation which may contribute to equipment failure.
3. Pipe unions and isolation valves are recommended on both water connections for ease of
service.
4. Install piping so that the boiler is not supporting any additional piping.
5. The top water connection on the back of the boiler is the hot water inlet and must be connected
as the return from the system. The bottom connection is the ow/boiler outlet.
6. Install a hot water circulator, remote mounted from the boiler. Do not attach directly to the boiler.
7. If the boilers are connected to heating coils, located in air handling units where they may be
exposed to refrigerated air circulation, such boiler piping system shall be equipped with ow
control valves or other automatic means to prevent gravity circulation of the boiler water during
the cooling cycle.
8. The boiler is not provided with a drain valve directly on the boiler. A drain valve should be
installed near the system return (water inlet) connection to the boiler and piped to a drain.
9. Before installing a FHE-250 boiler into a hydronic loop, be sure that the system piping and
any other components of the system are clean and free of debris and any foreign matter. The
hydronic system should be completely ushed prior to installing the boiler itself. Install a strainer
upstream of each boiler to ensure that no foreign matter will have the opportunity to get inside
the heat exchanger.
WARNING
The boiler must be disconnected at the boiler shut off valve from the
gas supply piping system during any pressure testing of the system.
!
CAUTION
Small levels of chlorides and/or sulphur presence in the combustion air or fuel will negatively impact
the heat exchanger components. Any presence of these contaminants will void the warranty.
!
CAUTION
Some soaps used for leak testing are corrosive to certain types of metals. Rinse all piping thoroughly
with clean water after leak check has been completed.
!
2.4 WATER PIPING INSTALLATION

FHE-250 MANUAL 09 2014 ISSUE 2
Page 8
2
These boilers incorporate a STAINLESS STEEL heat exchanger. For water conditions, please refer
to Section 5.4 - Recommended Water Conditions.
CAUTION
Heat exchanger failure due to inappropriate water quality, foreign matter or debris damage is not
covered under the warranty.
CAUTION
If the piping system attached to this unit will be chemically cleaned, the boiler must
be disconnected from the system and a bypass installed so that the chemical cleaning
solution does not circulate through the boiler.
CAUTION
The hydronic system should never be ushed while the boiler is attached to the system
since the debris could accumulate in the boiler and block water from passing through the heat
exchanger. This will lead to premature boiler failure.
!
!
!
Frost protection mode will be initialised when the boiler temperature sensor readings drop to 5°C.
The boilers will re until the water temperature reaches 15°C. Upon reaching 15°C the pumps will
continue to run for the pre-set duration of their overrun (specied by parameter “P 07” in Installer+
mode).
!
WARNING
The application of any other treatment to this product other than those recommended by Fulton Ltd
may render the guarantee of Fulton Ltd invalid.
!
CAUTION
Care needs to be taken to eliminate oxygen from the water system as excess oxygen in the system will
reduce the life of any boiler. The boiler warranty does not cover heat exchanger replacement due to
oxygen contamination of boiler water.
2.5 WATER TREATMENT
1. It is most important that the correct concentration of the water treatment products is maintained
in accordance with the manufacturers’ instructions.
2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by
thorough cleansing.
3. In hard water areas, treatment to prevent limescale may be necessary.
4. Under no circumstances should the boiler be red before the system has been thoroughly
ushed.
2.6 FROST PROTECTION
2.7 PREVENTING OXYGEN CONTAMINATION
1. There are several ways to prevent boiler water oxygen contamination:
2. Minimise system leaks to minimise make up water requirement
3. Do not use open tanks or ttings
4. Do not use oxygen permeable materials anywhere in the water system
5. Repair leaks in the system quickly
6. Eliminate ttings wherever possible

FHE-250 MANUAL 09 2014 ISSUE 2
Page 9
2
There is a factory-installed AAV (automatic air vent) on the heat exchanger.
The AAV must not be altered or removed.
The local gas supplier should be consulted at the installation planning stage in order to establish
the availability of an adequate supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier, in UK by a Gas Safe Registered
Engineer or in IE by a competent person.
An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is
adequate to deal with the dynamic rate of gas supply required. A minimum working gas pressure of
6.5 mbar MUST be available at the boiler inlet for Natural Gas.
Do not use pipes of a smaller size than the boiler inlet gas connection.
The complete installation MUST be tested for gas soundness and purged in accordance with the
appropriate standards.
Gas Boosters
A gas booster is required if the gas pressure available at the boiler is lower than 6.5 mbar. Boosted
gas supplies should not exceed 20 mbar.
Location of the booster requires careful consideration but should preferably be closer to the burner
rather than the gas meter. Ventilation should also be considered to ensure ambient temperatures do
not exceed designed recommendations. Further guidance is provided in IGEM/UP/2 (Institution of
Gas Engineers and Managers-Installation pipework on industrial and commercial premises.
Communication number 1729).
2.8 ELIMINATING SYSTEM AIR
2.9 FILLING THE BOILER WITH WATER
2.10 GAS SUPPLY
Adhere to the following:
1. Once the boilers have been installed and connected to the distribution system, open the
isolating valves on each boiler, the AAV’s (automatic air vents) will vent any excess air in the
system.
2. Visually inspect all pipe joints and equipment connections for leaks. If necessary, drain system,
repair leaks and rell/purge the system. If no pressure drop is detected for a period of two hours
under pressure, the system may be considered watertight.
3. When purging is completed, make sure the following are open: combination shut-off/purge valve,
shutoff valve to pressure reducing (ll valve), shutoff valve in cold water ll line, and shutoff
valve in return line.
4. Make sure the following are closed: all drain cocks, the vent on the combination shutoff purge
valve, and all manual vents.
5. Open fuel shut-off valve, allowing fuel to ow to boiler.

FHE-250 MANUAL 09 2014 ISSUE 2
Page 10
2
WARNING
Do not use any source of ignition to check for gas leaks
!
CAUTION
Some soap used for leak testing is corrosive to certain types of metals.
Clean all piping thoroughly after completing the leak check.
!
CAUTION
Never leave an opened manual air vent unattended.
In the event that an opened vent is left unattended, water damage could occur.
!
CAUTION
The presence of chlorides and/or sulphur in the combustion air or fuel
will negatively impact the heat exchanger and void the warranty.
!
The gas supply pipe terminates in a 28 mm copper pipe connection on each 250 model. Common
gas supply pipe sizes for connection to multiple boiler modules are available on request from Fulton.
1. A minimum working gas pressure of 6.5 mbar must be available at the boiler inlet with the
boiler ring.
2. Fit a gas supply pipe at an appropriate size in order to limit the pressure drop between the
meter outlet and connection to the boiler(s) to 1 mbar (100 Pa) max.
3. All gas supply pipework must be independently supported.
4. The boiler and all gas piping connections must be pressure-tested and checked for leaks
before being placed into service. Test with compressed air or inert gas if possible.
5. The boiler must be disconnected at the boiler manual shutoff valve (located near the end of
the supplied gas train at the front of the boiler) from the gas supply piping system during any
pressure testing of the system at pressures in excess of 35 mbar (3.5 Pa).
6. Gas piping must be installed in accordance with all relevant gas codes and any other local
codes which may apply.
7. The pipe and the ttings used must be new and free of dirt or other deposits.
8. After gas piping is completed and before wiring installation is started, carefully check all
piping connections, (factory and eld), for gas leaks. Use a soap and water solution.
2.10.1 GAS CONNECTION

FHE-250 MANUAL 09 2014 ISSUE 2
Page 11
2
FIG. 3 TYPICAL GAS TRAIN
Modulating
Gas Valve
Inlet to
Modulating
Gas Valve
Isolating
Valve

FHE-250 MANUAL 09 2014 ISSUE 2
Page 12
2
Working pressure 6 bar maximum, 1 bar minimum.
Particular reference should be made to BS. 6644, Guidance note BG01 “Guidance on safe operation
of boilers” and “INDG436 “Safe management of industrial steam and hot water boilers”, published by
the Health and Safety Executive.
The information and guidance given below is not intended to override any requirements of either of
the above publications or the requirements of the local authority, gas or water undertakings.
In general commercial closed pressurised systems are provided with either manual or automatic
water make up.
In both instances it will be necessary to t automatic controls intended to protect the boiler, circulating
system and ancillary equipment by shutting down the boiler plant if a potentially hazardous situation
should arise.
Examples of such situations are low water level and operating pressure or excessive pressure within the
system. Depending on circumstances, controls will need to be either manual or automatic reset. In
the event of a shutdown both visual and audible alarms may be necessary.
Expansion vessels used must comply with EN 13831 and must be sized on the basis of the total
system volume and initial charge pressure.
Initial minimum charge pressure should not be less than 1.0 bar (100 kPa) and must take account of
the static head and specication of the pressurising equipment.
When make up water is not provided automatically it will be necessary to t controls which shut down
the plant in the event of the maximum system pressure approaching to within 0.35 bar (35 kPa) of
the safety valve setting. Other British Standards applicable to commercial sealed systems are:
BS. 6880: Part 2 BS. 1212 BS. 6281: Part 1 BS. 6282: Part 1 BS. 6283: Part 4
2.11 SEALED SYSTEM REQUIREMENTS

FHE-250 MANUAL 09 2014 ISSUE 2
Page 13
2
Adequate fresh, clean air is necessary for safe and efcient combustion, and should be provided at
high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part 1 Communication 1676.
Note:
a) Ensure there is adequate ventilation in the boiler room. Lack of ventilation will create a high temperature and
cause control lockout.
b) Where mechanical ventilation is provided for plantrooms, ensure positive pressurisation of the space is
always maintained - hazardous interlock with the boiler may be required for this purpose.
c) Do not store chemicals such as perclorethylene in the boiler house, the fumes may damage the boiler and
ue and cause the burner to lock out on ame failure. The ventilation requirements of these boilers are
dependant on the type of ue system used, and their heat input. All vents must be permanent with no means
of closing, and positioned to avoid accidental
obstructions by blocking or ooding.
Detail reference should be made to BS. 6644 for inputs between 70 kW and 1.8 MW (net).
In IE refer to the current edition of I.S.820:2000. The following notes are for general guidance only:
Dust contamination in the combustion air may cause blockage of the burner slots. Unless the boiler room
provides a dust free environment then direct connection of the air intake via ducting to clean outside
air should be used.
IMPORTANT NOTE: If combustion air is drawn from within the boiler room, ensure no dust or airborne debris can
be ingested into the appliance. Dusty concrete ooring should be sealed to reduce the presence of dust.
The temperature within a boiler room shall not exceed 25°C within 100 mm of the oor, 32°C at mid
height and 40°C within 100 mm of the ceiling.
Open Flued Installations
If ventilation is to be provided by means of permanent high and low vents communicating direct with
outside air, then reference can be made to the sizes below. For other ventilation options refer to BS.
6644. In IE refer to the current edition of I.S.820.
Required area (cm2) per kW of total rated input (net)
Note: Where a boiler installation is to operate in summer months (e.g. DHW), additional ventilation requirements
are stated within BS6644 if operating for more than 50% of the time.
Boiler Room Enclosure
Low Level (Inlet) 4 10
High Level (Outlet) 2 5
2.12 VENTILATION
Required area (cm2)
Boiler Room
FHE-250 FHE-500 FHE-750 FHE-1000
Low Level (Inlet) 1020.4 2040.8 3061.2 4081.6
High Level (Outlet) 510.2 1020.4 1530.6 2040.8
Enclosure
FHE-250 FHE-500 FHE-750 FHE-1000
Low Level (Inlet) 2551 5102 7653 10204
High Level (Outlet) 1275.5 2551 3826.5 5102

FHE-250 MANUAL 09 2014 ISSUE 2
Page 14
2
Combining multiple FHE-250 boilers into a common ue or duct for combustion air supply,
exhaust, or both is only permitted on a case by case basis and must be accomplished with an
engineered solution. Please contact Fulton for details/designs.
Adhere to the following:
1. There is an integral combustion air supply damper within the unit, complete with a magnetic
switch that is fully integrated into the standard boiler controls, to prevent ue gases from
entering the plantroom.
2. FHE-250 boilers should not be common vented with other types of equipment.
WARNING
Fulton cannot assume responsibility for an air intake or exhaust
arrangement where FHE-250 boilers are common vented with any other type of equipment.
!
1. Air intake ducting must be sized in conjunction with the exhaust venting to provide no greater
than a 2 mbar (200 Pa) combined pressure drop. Refer to Section 2.14.1 - Flue System
Design for further details and guidance on this issue.
2. Each FHE-250 module with internal intake ducting incorporates a coarse air lter. The
installation of a recognised termination screen is required on all combined air intakes for
multiple boiler modules.
3. Air intake ducts and ttings shall be galvanised steel or Schedule 30 PVC pipe.
Note: where these boilers are to be room-sealed,the internal air inlet ductwork and ttings and external connector
for ducted connections are all in galvanised steel.
4. If using PVC, all intake PVC piping must be assembled using suitable cement. This will
ensure that the intake is airtight and will not allow contaminants from the boiler room into the
boiler.
5. Air intake terminations must be suitably weatherproofed to prevent ingress of moisture into
the system.
2.12.1 COMMON AIR INTAKE AND EXHAUST VENTING OF MULTIPLE BOILERS
2.12.2 INTAKE DUCT SIZING