FULTON PHW 300 User manual

INSTALLATION AND
OPERATION MANUAL
Gas Pulse Combustion
Hydronic Heating Boiler (PHW)
Serial/National
Board #
Model
Fulton Order
Sold To
Job Name
Date
PHW-IOM-2013-0214

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PHW-IOM-2013-0214 TABLE OF CONTENTS
0-1
Introduction 1-1
Overview.............................................................................................................. 1-2
Warnings & Cautions............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Product Overview................................................................................................. 2-2
Review Shipment Contents.................................................................................. 2-2
Placement & Rigging........................................................................................... 2-3
Clearances and Serviceability .............................................................................. 2-5
Install Isolation Mounts ....................................................................................... 2-5
HOWTO INSTALL ELASTOMER CUBE ISOLATION MOUNTS........................................................25
HOWTO INSTALL SPRING ISOLATION MOUNTS.........................................................................26
HOWTO INSTALL SEISMIC SPRING ISOLATION MOUNTS...........................................................27
Install BoilerTrim ................................................................................................. 2-8
Water Chemistry Requirements........................................................................... 2-8
Install Water Piping.............................................................................................. 2-9
Install Condensate Drain.................................................................................... 2-11
INSTALL CONDENSATE DRAIN PIPING .....................................................................................212
Install pH Neutralization Kit............................................................................... 2-12
Install Gas Piping................................................................................................ 2-14
Install FieldWiring ............................................................................................. 2-14
Air Intake Supply Piping Installation Preparation.............................................. 2-15
CEMENTING JOINTS...................................................................................................................216
Install Intake Muer ......................................................................................... 2-17
Preparing to Install ExhaustVent Piping............................................................ 2-17
Exhaust Muer Installation .............................................................................. 2-18
Air Intake & Exhaust Piping Requirements for the Pulse Boiler ........................ 2-19
Air Intake Supply and ExhaustVent Installation ............................................... 2-20
VerticalVent Flashing and Installation .............................................................. 2-21
VerticalVent Termination .................................................................................. 2-21
Horizontal InstallationWall Penetrations ......................................................... 2-24
WallThimble Installation .................................................................................. 2-24
HorizontalVentTermination ............................................................................. 2-25
After Installation/Prior to Start-Up.................................................................... 2-26
Installation Checkpoints ................................................................................... 2-28
Testing Ignition Safety Shut O ........................................................................ 2-28
Measure Gas Flow Rate ..................................................................................... 2-28
TO CORRECT INPUT  ADJUST GAS PRESSURE REGULATOR....................................................229
Rating the Boiler................................................................................................ 2-29
To Check for High Gas Pressure .......................................................................... 2-29
For High Gas Pressure Installations Using Fisher Regulators ............................. 2-29
Before Leaving the Installation ......................................................................... 2-30
Operation 3-1
Before Start Up..................................................................................................... 3-2
Start Up................................................................................................................ 3-2
LINKAGE ADJUSTMENT FOR PULSE MODULATED BOILERS.......................................................33
IFTHE BOILER DOESN’T START ..................................................................................................35
Sequence of Operation for Modulated Pulse Hydronic Boilers............................ 3-6
General Operation of the Boiler ........................................................................... 3-6
Programming Instructions for the SOLA Control ................................................. 3-6
CHANGING/TESTING SOLA HIGH LIMIT SETPOINT ..................................................................310
VERIFYING CHANGESTO HIGH LIMIT SETPOINT .....................................................................310
ACCESSING LOCKOUT HISTORY AND CLEARING LOCKOUTS.....................................................311
PROCEDURE FOR REMOTE FIRING RATE USING A 420MA SIGNAL SINGLE BOILER ...........312
PROCEDURE FOR REMOTE SETPOINT USING A 420MA SIGNAL SINGLE BOILER................313
PROCEDURE FOR LEAD/LAG WITH OUTDOOR RESETWITH MULTIPLE BOILERS....................314
SINGLE BOILER OUTDOOR RESET PROGRAMMING..................................................................318
Third Party SOLA Control.................................................................................... 3-21
LEAD/LAG OUTDOOR RESET CONFIGURATION USING COMMUNICATION PORT 2..................321
STAND ALONE BOILERS CONTROLLED BY ATHIRD PARTY CONTROL......................................321
GATEWAYS .................................................................................................................................321
Maintenance 4-1
General................................................................................................................. 4-2
Daily Maintenance and Inspection Schedule ...................................................... 4-2
Monthly Maintenance and Inspection Schedule................................................. 4-2
Annual Maintenance and Inspection Schedule................................................... 4-3
After All Repairs and Maintenance ...................................................................... 4-4
Troubleshooting................................................................................................... 4-5
Reviewing Diagnostics on SOLA Control.............................................................. 4-6
TAKING SCREEN SHOTS................................................................................................................47
Warranty & Parts 5-1
Standard Warranty for Fulton Pulse Boilers
with Carbon Steel Exhaust Pipes.......................................................................... 5-2
Standard Warranty for Fulton Pulse Boilers
with Duplex Stainless Steel Exhaust Pipes........................................................... 5-3
Parts..................................................................................................................... 5-4

© The Fulton Companies 2013
TABLE OF CONTENTS PHW-IOM-2013-0214
0-2

Questions? Call(315) 298-5121,or visitus onlineat www.fulton.com 1-1
INTRODUCTION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2013
1-2
INTRODUCTION PHW-IOM-2013-0214 SECTION 1
Overview
Prior to shipment, the following inspections and tests are
made to ensure the highest standards of manufacturing for
our customers:
§Material inspections
§Manufacturing process inspections
§American Society of Mechanical Engineers (ASME)
welding inspection
§ASME hydrostatic test inspection
§Electrical components inspection
§Operating test
§Final engineering inspection
§Crating inspection
This manual is provided as a guide to the correct operation
and maintenance of your Fulton equipment, and should be
read in its entirety and be made permanently available to the
sta responsible for the operation of the boiler. It should not,
however, be considered as a complete code of practice, nor
should it replace existing codes or standards which may be
applicable. Fulton reserves the right to change any part of
this installation, operation and maintenance manual.
Installation, start-up, and maintenance of this equipment
can be hazardous and requires trained, qualied installers
and service personnel. Trained personnel are responsible
for the installation, operation, and maintenance of this
product, and for the safety assurance of installation,
operation, and maintenance processes. Do not install,
operate, service or repair any component of this
equipment unless you are qualied and fully understand
all requirements and procedures.Trained personnel
refers to those who have completed Fulton Service School
training specic to this product.
When working on this equipment, observe all warnings,
cautions, and notes in literature, on stickers and labels, and
any additional safety precautions that apply. Follow all safety
codes and wear appropriate safety protection. Follow all
jurisdictional codes and consult any jurisdictional authorities
prior to installation.
Warnings & Cautions
WARNINGS and CAUTIONS appear in various chapters of this
manual. It is critical that all personnel read and adhere to all
information contained in WARNINGS and CAUTIONS.
§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
eectiveness.
All Warnings and Cautions are for reference and guidance
purposes, and do not substitute for required professional
training, conduct, and strict adherence to applicable
jurisdictional/professional codes or regulations.
Disclaimers and Local Codes
Installation of the equipment shall conform to all the
requirements or all national, state and local codes established
by the authorities having jurisdiction or, in the absence
of such requirements, in the US to the National Fuel Gas
Code ANSI Z2231/NFPA 54 latest edition, and the specic
instructions in this manual. Authorities having jurisdiction
should be consulted prior to installation.
When required by local codes, the installation must conform
to the American Society of Mechanical Engineers Safety Code
for Controls and Safety Devices for Automatically Fired Boilers
(ASME CSD-1).
The boiler heat exchanger is manufactured and stamped
in accordance with ASME Boiler and Pressure Vessel Code,
Section IV for a maximum allowable working pressure of 160
psig. Maximum allowable working temperature varies by
design (210 F for duplex; 240 F for carbon).

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INSTALLATION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2013
INSTALLATION PHW-IOM-2013-0214 SECTION 2
2-2
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
4 CAUTION
This boiler is certied for indoor
installation only.
This boiler is not designed for use in
systems where water is continuously
replenished. Mineral build-up may
occur on the heat transfer surfaces
and result in overheating and
possible heat exchange failure. The
warranty is valid for closed loop
systems only.
Fulton cannot be held responsible
for the selection, engineering,
installation, or sizing of any
additional equipment or components
of the hydronic heating system.
This boiler, when installed in
conjunction with a refrigeration
system, must be installed so that the
chilled medium is piped in parallel
with the boiler with appropriate valves
to prevent the chilled medium from
entering the boiler. 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 systems must be
equipped with ow control valves or
other automatic means to prevent
gravity circulation of the boiler water
during the cooling cycle.
Product Overview
Prior to the performance of installation, operation, or maintenance procedures,
personnel should become familiar with the equipment (Table 1, Figures 1 and 2)
and its components.
The Fulton Pulse combustion hydronic boiler is an automatic gas red, direct
vent boiler. This boiler utilizes pulse
combustion principle. It does not
have conventional burner controls
or chimney. The combustion
components are of integral design
with the heat exchanger. Each boiler
is built to ASME and CSD-1 Codes,
hydrostatically tested, test red, and
shipped as a complete packaged
unit.
All installations must be in
accordance with the American
National Standard“National Fuel
Gas Code,”latest edition, and with
the requirements of local utilities or
other authorities having jurisdiction.
Such applicable requirements
take precedence over the general
instructions herein.
Since an external electrical source
is utilized, the boiler must be
electrically grounded in accordance
with the National Electrical Code,
ANSI/NFPA 70-latest edition.
In some cases the approval authority may insist that the installation conform to
the American Society of Mechanical Engineers ASME safety standard for controls
and safety devices for automatically red boilers, or CSD-1. In Canada, gas
installations must be in accordance with the current CAN/CGA B149.1 and .2 and/
or local codes. Electrical installations must be installed in accordance with the
current CSA C22.1 Canadian Electrical Code and/or local codes.
Review Shipment Contents
Your Fulton Pulse Boiler shipment should be fully reviewed upon receipt. The
following are standard and accessory items that may be included with your
shipment.
The customer should also examine the equipment for any shipment damage.
It is the responsibility of the installer to ensure all parts supplied with the
equipment are tted in a correct and safe manner.
This Boiler is a Direct Vent Boiler for
Installations on Non-Combustible Floors Only
Fulton Gas Fired
Pulse Combustion Boiler
Manufactured by
Fulton Heating Solutions, Inc.
Pulaski, New York 13142
Maximum Gas Supply Pressure: 14 Inches W.C.
Minimum Permissible Gas Supply Pressure for Purpose of
Input Adjustment: 7 Inches W.C. 11 Inches W.C.
Electrical Ratings: 120 V/60 Hz/Less than 15 Amps
Conforms to ANSI Std. Z21.13 __________
Certified to CSA Std. 4.9__________
Wall Thickness Through Which Vent System May
Be Installed: 31
/
4
Inches Min. / 20 Inches Max.
Minimum Clearance to Combustibles:
1 Inch (Sides) / 24 Inches (Top, Front & Rear)
Type of Gas: Natural Propane
Boiler Model No.
Boiler National Board No.
Year
Min. BTU Input/Hr. Min. BTU Output/Hr.
Max. BTU Input/Hr. Max. BTU Output/Hr.
Design Pressure PSI
Mimimum Relief Valve Capacity: Pounds/Hr.
Manifold Gas Pressure: Inches W.C.
FIGURE 1  PULSE BOILER PLATE

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SECTION 2 PHW-IOM-2013-0214 INSTALLATION
2-3
}STANDARD TRIM
The following items are standard trim for Fulton Pulse Combustion Hydronic
Boilers:
§Microprocessor Based Control - 120 volt with built-in operating and high
limit controls, and separately wired dual element sensor
§Low Water Cuto (Probe Type)
§Control Panel Completely Wired with Diagram
§Gas Pressure Switches
§Spark Ignition
§Factory-Assembled and Mounted Fuel Train
§Flame Rod
}PACKAGED SEPARATELY
Included with and packaged separately with each boiler are the following
components:
§ASME Pressure Relief Valve
§Pressure-Temperature Gauge
§Air Intake Pipe Adaptor
§Installation, Operation, and Maintenance Manual
§Elastomer Coated Fiberglass Cubes or Springs For Mounting
§Gas and Water Flex Connectors
§Intake and Exhaust Muers
§1 Can Touch-up Paint
}OTHER ACCESSORIES
Other items that may be included are:
§Condensate Drain - one condensate drain kit can accommodate the
condensate from up to 12 MM BTUs.
§PH Neutralization Kit
Placement & Rigging
Proper placement of your Fulton product is essential. Correct placement is the
rst step to trouble-free installation, operation, and maintenance.
Adhere to the following for placement and rigging:
1. Check building specications for permissible oor loading. Use Table 1 for
unit reference.
2. Conform to all the requirements of all national, state and local codes
established by the authorities having jurisdiction and/or the U.S. to the
National Fuel Gas Code, latest edition. Authorities having jurisdiction
should be consulted before installations are made. Where required by local
codes, the installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for Automatically
Fired Boilers (ASME CSD-1).
3. Since an external electrical source is utilized, the boiler, when installed,
must be electrically ground in accordance with the National Electric Code,
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
Competent personnel in accordance
with all applicable local codes should
carry out the installation of the Fulton
equipment. All state and jurisdictional
codes beyond the scope of the applicable
ASME Boiler and Pressure Vessel Codes,
for its corresponding classication, should
be followed in all cases. Jurisdictional
authorities must be consulted prior to
installation.
A competent rigger experienced in
handling heavy equipment should handle
rigging your equipment into position.
The equipment must be installed on a
non-combustible surface.
Failure to provide required and safe
access to the equipment could impede
commissioning and maintenance.
Service technicians are instructed not to
commence commissioning if hazardous
conditions exist.
Failure to provide proper minimum
clearances between equipment and
combustible materials may result in re.
4 CAUTION
Do not allow weight to bear on equipment
components to prevent damage.

© The Fulton Companies 2013
INSTALLATION PHW-IOM-2013-0214 SECTION 2
2-4
TABLE 1 - BOILER DIMENSIONS AND OPERATING REQUIREMENTS
Model PHW 300 500 750 1000 1400 2000
Specications
Input BTU/Hr 300,000 500,000 750,000 1,000,000 1,400,000 2,000,000
Nat. Gas consumption @ rated
capacity
FT3/Hr 300 500 750 1000 1400 2000
Propane Consumption @rated
capacity
FT3/Hr 120 200 300 400 560 720
Electrical Requirements 120V/60/1 4.2/0.6 4.2/0.6 4.2/0.6 4.2/0.6 4.2/0.6 10/.75
(Amps: Max/Run) 240V/60/1 2.1/0.3 2.1/0.3 2.1/0.3 2.1/0.3 2.1/0.3 5/0.4
MAWP PSI 160 160 160 160 160 160
BAR 4.1/11.0 4.1/11.0 4.1/11.0 4.1/11.0 4.1/11.0 4.1/11.0
Water Content Gal 34 34 42 42 80 75
Dry Weight LB 1395 1395 1800 1800 2230 2900
Operating Weight LB 1680 1680 2150 2150 3195 3500
Dimensions
A. Boiler Width IN 27.5 27.5 27.5 27.5 33.6 33.6
B. Overall Boiler Height IN 71.25 71.25 83.2 83.2 88.1 89
C. Overall Boiler Depth IN 53.25 53.25 51.3 51.3 62.6 70.1
D. Exhaust Outlet Diameter IN 4 4 4 4 4 6
E. Air Inlet Diameter IN 3 3 4 4 4 6
F. Water Inlet/ Outlet Diameter IN 2 2 2 2 2.5 4 Flanged
G. Min. Clearance to Ceiling IN 24 24 24 24 24 24
H. Min. Clearance to Either Side Wall IN 1 1 1 1 1 1
I. Min. Clearance in Front of Boiler IN 36 36 36 36 36 36
J. Min. Clearance Behind Boiler IN 24 24 24 24 24 24
FIGURE 2 -PULSE COMBUSTION HYDRONIC BOILER
Back View
Front View Top View
A
C
D
B
G
E
H
F
F
I J

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SECTION 2 PHW-IOM-2013-0214 INSTALLATION
2-5
American National Standards Institute (ANSI) National Fire Protection
Association (NFPA) 70, latest edition.
4. Install so that all system components are protected from water (dripping,
spraying, rain, etc.) during boiler operation and service.
5. Install on a level, non-combustible surface in the vertical position. Concrete
is strongly recommended.
6. Provide combustion and ventilation air in accordance with applicable
provisions of local building codes or: USA – NFPA 54/ANSI Z223.1, Section
5.3, Air for Combustion and Ventilation.
7. Locate the boiler so that the air supply and exhaust piping between
the boiler and outside wall/roof are within length or pressure drop
requirements. See Clearances and Serviceability section of this manual.
Clearances and Serviceability
Adhere to the following for clearances and serviceability:
1. All local and national codes (NFPA, ANSI, UL, ETL, ASME, CSA) must be
followed for proper clearances and serviceability for your boiler or heater.
Authorities having jurisdiction should be consulted before installations are
made.
2. Appropriate front, back, side and top clearances must be maintained
(Figure 2, Table 1). This will allow access around the equipment to facilitate
maintenance and a safe work environment. An 1 inch (25.4 mm) side
clearance is acceptable between boilers. Custom congurations may not
allow 1 inch (25.4 mm) side clearance.
3. Ensure all labels on the boiler will be fully visible for maintenance and
inspection.
Install Isolation Mounts
All pulse combustion boilers must be installed with vibration isolators. No
pulse combustion boiler shall be lagged directly to the concrete oor due to
the transfer of vibration. For installations near“sensitive”areas such as oces,
classrooms, or hospital rooms, spring mounts - which t under the corner of each
boiler - must be used instead of the cubes.
¡How to Install Elastomer Cube Isolation Mounts
Adhere to the following for elastomer cube isolation mounts (see Figure 3):
1. Locate in the box of trim shipped with each Pulse boiler the 4 elastomer
cubes (3”x 3”x 2”) used for vibration isolation.
2. Insert these cubes under each foot of the boiler.
! WARNING
Do not install this boiler in an uncontrolled
environment where condensate will be
subject to freezing temperatures.
4 CAUTION
Do not install this boiler on carpeting.
Install boiler such that gas ignition system
components are protected from water
(dripping, spraying, rain, etc.) during boiler
operation and service.

© The Fulton Companies 2013
INSTALLATION PHW-IOM-2013-0214 SECTION 2
2-6
NOTE:´Flex connectors must be installed on the gas supply, water inlet and
water outlet lines. Spring loaded pipe hangers should be used on the air
inlet and the ue gas vent.
NOTE:´Contact your Fulton Representative for vibration isolation packages
designed specically for your application.
¡How to Install Spring Isolation Mounts
Adhere to the following for Spring Isolation Mounts (see Figure 4):
1. Thread the leveling bolt into the top load plate of the spring until the head
of the bolt is within 1/8”of the top load plate of the spring.
2. Coordinate the location of each isolator.
3. Remove the small cap screw and washer. Raise the boiler with jacks or
similar tools. Do not attempt to raise the boiler via one lifting point, but lift
evenly around the perimeter of the boiler). Slide the spring isolator under
the boiler or mounting bracket with the bolt head on the underside of the
bracket.
4. Insert the small cap screw through the bracket and thread into the top of
the leveling bolt and tighten nger tight.
5. Lower the boiler (evenly) onto the spring isolators. Do not overload any
one isolator and take care not to push the boiler sideways.
6. Do not attempt to place all the weight on one spring, but distribute the
load proportionately by adjusting each isolator in sequence.
7. Continue to adjust each leveling bolt (in sequence) until the boiler is at
its proper height. When the boiler is lled with water, the springs will
compress approximately 1-2”.
8. Tighten the small cap screw, thus securing the spring isolator to the
supported equipment and locking the leveling bolt against turning.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
4 CAUTION
Do not attempt to move the boiler laterally
while it is supported on isolators. Bent or
broken leveling bolts or springs, or damage
to the neoprene bottom spring cap could
result.
Do not install the boiler in an uncontrolled
environment where the condensate will be
subject to freezing temperatures.
FIGURE 3 - INSTALLING ELASTOMER CUBE ISOLATION MOUNTS

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SECTION 2 PHW-IOM-2013-0214 INSTALLATION
2-7
! WARNING
The discharge from the safety relief
valve must be arranged to ensure
no danger of scalding personnel, or
equipment damage.
Provisions must be made to properly
pipe the safety relief discharge
away from the boiler to the point of
discharge.
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.
Ensure all labels on the boiler are
legible. All connections and safety
devices, both mechanical and
electrical, must be kept clean, with
ease of access for inspection, use and
maintenance.
Do not store or use gasoline or other
ammable vapors and liquids or
corrosive materials in the vicinity of
this or any other appliances.
NOTE:´Do not attempt to move the boiler laterally while it is supported
on the isolators. If it is necessary to move the boiler remove the weight
from the isolators by raising the boiler before moving. Failure to follow
this procedure could result in bent or broken leveling bolts or springs, or
damage to the neoprene bottom spring cap.
¡How to Install Seismic Spring Isolation Mounts
Adhere to the following for installation of Seismic Spring Isolation Mounts (see
Figure 5):
1. Thread the leveling bolt 1/2”into the top of the load cap.
2. Remove the lock nut and one washer from the top of the leveling bolt.
Locate leveling nut as far down on leveling bolt as it will travel.
3. Coordinate the location of each isolator.
4. Place a one inch shim next to each bracket between the boiler and the
housekeeping pad or structural oor. If an operating clearance of other
than one inch is desired, use an appropriate size shim.
5. Raise the boiler and slide the spring isolator under the equipment
mounting bracket with the leveling nut and one washer on the under side
of the bracket.
6. Lower the boiler onto the spring isolators taking care not to overload any
one isolator and taking care not to push the boiler sideways.
7. Install second washer and lock nut one inch down from top of leveling
bolt.
8. Turn the leveling nut in a counter-clockwise rotation until the boiler
just touches the shim. The shim may now be removed. Proceed with
adjustment of the other three isolators.
9. Tighten the lock nuts on the leveling bolts, thus bolting the spring to the
boiler and locking the leveling bolt against turning.
FIGURE 4 - INSTALLING SPRING ISOLATION MOUNTS

© The Fulton Companies 2013
INSTALLATION PHW-IOM-2013-0214 SECTION 2
2-8
! WARNING
Discharge from the safety relief valve
must be arranged so that there is no
danger of scalding. When the safety
relief valve is piped away from the
boiler to the point of discharge, there
must be provisions to properly drain
the piping.
No shuto of any kind may be placed
between the safety relief valve and
the boiler, or on the discharge pipe
between the safety relief valve and
the atmosphere. Doing so may
cause an accidental explosion from
overpressure.
4 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.
Heat exchanger failure due to
inappropriate water quality, foreign
matter or debris damage is not covered
under the warranty.
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.
NOTE:´Do not attempt to move the isolators laterally with the weight of the
boiler on them. If it is necessary to move the boiler, remove the weight from
the isolators by raising the equipment before moving.
Install Boiler Trim
Each boiler is supplied with a safety relief valve sized in accordance with ASME
requirements.
Adhere to the following for installation:
1. Connect the safety relief valve to the coupling located in the top of the
boiler. 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 discharge pipe shall
be not less than the full area of the valve outlet. The discharge pipe shall be
as short and straight as possible and so arranged as to avoid undue stress
on the valve.
2. Install pressure-temperature gauge in the side port of a tee installed in the
boiler water outlet. A tee is installed on the nipple.
Water Chemistry Requirements
All water supplies contain some amount of solids, dissolved gases and dissolved
minerals. These materials may promote corrosion, deposition and/or fouling
of equipment. To prevent these contaminants from impacting on boiler
performance, valve operation and general pipe longevity, each location must be
analyzed and treated accordingly. The following are installation recommendations
for“closed-loop”recirculating hot water heating systems.
1. Automatic pressure activated water make up valve with backow preventer
providing water to the system, not fed directly to the boiler, set to maintain:
§Required NPSH for recirculating pump(s).
FIGURE 5 - INSTALLING SEISMIC SPRING ISOLATION MOUNTS

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SECTION 2 PHW-IOM-2013-0214 INSTALLATION
2-9
§A positive system pressure at the highest point of 5 to
10 psi.
§Make up water valve should be designed to add water
to the system at the outlet of the boiler and should
not be fed directly into the boiler.
2. Air removal equipment, including air separator and
automatic air breather valves.
3. A functioning expansion tank designed to system
specications.
4. Filtration to remove particulates installed inline with the
suction side of the recirculating pump.
5. Bypass chemical feeder for corrosion inhibitor
maintenance.
6. Optionally a water meter could be installed in series
with the automatic pressure activated water make up
valve to monitor any make up water.
7. Ensure water quality meets the following:
§Oxygen - less than 250 ppb (operating condition)
§pH - must be in the range of 8-10
§Total Iron & Copper - less than 25 ppm
§Corrosion Inhibitor - level capable of maintaining
iron corrosion rates < 2 mpy. Due to changing
environmental restrictions, a non-heavy metal, all
organic inhibitor is recommended, which is designed
for multi-metal systems including ferrous metals and
yellow metals such as copper and brass.
§Chlorides - less than 250 ppm as Cl. Limit applicable
only to installations utilizing duplex steel pressure
vessel components.
Install Water Piping
The bottom connection to the boiler is the INLET and must be
connected as the return from the system. The top connection
on the boiler is the OUTLET and must be connected as the
supply to the system.
ADDITONAL
BOILER (S)
HEATING
SUPPLY
MANIFOLD
ADDITIONAL
BOILER (S)
HOT WATER
STOP VALVE
TEMPERATURE
PRESSURE
GAUGE
OPERATING AND
HIGH LIMIT AQUASTATS
(INTERNAL)
ASME
SAFETY
VALVE
STOP
VALVE
DRAIN
CONDENSATE
DRAIN
Multiple Boiler Installation
TYPICAL PIPING SYSTEM
UNLESS OTHERWISE NOTED, ALL
COMPONENTS SHOWN ARE TYPICAL
ON EACH BOILER
HEATING
RETURN
MANIFOLD
EXPANSION
TANK
STOP
VALVE
CHECK
VALVE
PRESSURE
REDUCING
VALVE
MAKEUP
WATER
AUTOMATIC
AIR VENT
FLAME ROD
SPARK PLUG
FIGURE 6 - TYPICAL PIPING (MULTIPLE BOILER SYSTEM)

© The Fulton Companies 2013
INSTALLATION PHW-IOM-2013-0214 SECTION 2
2-10
Adhere to the following for water piping installation (Figure 6):
1. Connect hot water supply to heating system feed line.
2. Connect expansion tank.
3. Connect return water to boiler return water connection.
4. Install an air separator and air eliminator (air vent) which is necessary as
there is no built in boiler air eliminating feature.
5. If a sealed diaphragm-type expansion tank is used, install air eliminator in
hot water piping at air separator.
6. If an air cushion type expansion tank is used, pipe tank directly into boiler
supply.
7. On multi zoned systems (or a system with both space and domestic water
heating), air elimination must be provided either in the common piping or
every loop. When the boiler is installed at a higher level than baseboard
radiation, air elimination must be provided directly above the unit.
8. Install hot water circulator, remote mounted from boiler. Do not attach
directly to the boiler. Flexible connectors must be placed between the
circulator and the boiler.
NOTE:´For all models, a no ow condition will not damage the heat
exchanger, however, adequate ow should be provided to prevent tripping
the boiler on high temperature limit.
9. For boilers with carbon steel or duplex steel heat exchangers, the
maximum allowable temperature dierential across the heat exchanger
is 100 degrees F. Minimum outlet temperature for carbon steel units must
be 120 degrees F or greater. Maximum allowable working temperature for
carbon steel units is 240 F. High limit is set at 230 F, therefore operating at
a temperature greater than 220 F is not recommended. For duplex steel
units, maximum allowable working temperature is 210 F. High limit is set
at 200 F, therefore operating at a temperature greater than 190 F is not
recommended.
10. Install manual purging valves in all loops and zones. Install pressure
reducing (automatic ll) valve in the cold water ll line to the boiler system.
11. Check that the proposed operation of zone valves, zone circulator(s) and
diverting valves will not isolate air separator(s) and/ or expansion tank(s)
from the boiler.
12. Clearance from hot water pipes to combustibles must be at least 6”.
13. The boiler, when used in conjunction with a refrigeration system, must
be installed so the chilled medium is piped in parallel with the boiler
with appropriate valves to prevent the chilled medium from entering the
boiler. 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 systems shall be equipped with ow control valves or other
automatic means to prevent gravity circulation of the boiler water during
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
Do not use matches, candles, ame or
other sources of ignition to check for gas
leaks.
If the water supply must be temporarily
disconnected from the condensate
trap, the boilers must be turned o to
prevent accidental ue gas emission
into the boiler room. An uninterruptible
water supply is required and shall be
connected to the ¼” compression tting
on the condensate drain. The water supply
maintains a water level in the drain kit to
prevent accidental ue gas emission into
the boiler room.
Cements for plastic pipe are ammable
liquids and should be kept away from all
sources of ignition. Proper ventilation
should be maintained to reduce the
hazard and to minimize breathing of
cement vapors. Avoid contact of cement
with skin and eyes.
4 CAUTION
Some soap used for leak testing is corrosive
to certain types of metals. Clean all piping
thoroughly after completing the leak check.

Questions? Call(315) 298-5121,or visitus onlineat www.fulton.com
SECTION 2 PHW-IOM-2013-0214 INSTALLATION
2-11
the cooling cycle.
14. The boiler is furnished with a probe type low water
cuto. No eld piping is required. If the probe does
not sense water, the boiler will shut down and a red
indicator will be illuminated on the control panel.
15. The boiler is not provided with external drain
connections. A drain valve must be installed near the
inlet connection to the boiler and piped to a suitable
oor drain. A Boiler Drain Assembly can also be
purchased from Fulton. This Boiler Drain Assembly must
be installed near the inlet connection to the boiler.
16. Before lling the boiler clean and ush the system
to remove any debris. Clean and ush old piping
thoroughly before installing the boiler. Consider
installing a strainer ahead of the boiler.
Install Condensate Drain
The condensate drain kit is intended for use 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 drain lines may be connected to this inlet
(maximum of 12 MM BTU/hr) through a common header. See
Figure 7.
Adhere to the following for installation:
1. An uninterruptable water supply is required and shall
be connected to the 1/4”compression tting on the
drain oat. The water supply maintains a water level in
the drain kit to prevent the ue gas from entering the
boiler room through the condensate connection. The 1
1/2”connection shall be piped to an appropriate drain
for disposal. If the water supply must be temporarily
disconnected, the boiler(s) must be turned o to
prevent accidental ue gas emission into the boiler
room.
2. Keep the cover on at all times, except during
maintenance of the drain. This drain should be
monitored and checked regularly in your Pulse
maintenance schedule.
3. A condensate collecting tank and condensate pump
FIGURE 7 - MULTIPLE BOILER CONDENSATE DRAIN INSTALLATION

© The Fulton Companies 2013
INSTALLATION PHW-IOM-2013-0214 SECTION 2
2-12
will be required if a oor drain is not available to discharge to (Collecting
tank and pump are not supplied with the boiler). Complete condensate
drain kits are available from Fulton.
¡Install Condensate Drain Piping
Adhere to the following when installing condensate drain piping:
1. All piping must be galvanized or stainless steel and should be free of leaks.
2. Make sure either elastomer coated berglass cubes or spring mounts have
been installed under each leg of the boiler.
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.
The header must be at least 5 ½”below the condensate outlet of the
individual boiler and must remain ooded by being at least 5 ½”below the
outlet of the condensate drain trap..
5. Connect 1½”drain outlet to an appropriate waste line following applicable
codes. The 1½”drain connection on the condensate drain must be the
highest point prior to going to the drain. Failure to keep drain piping lower
than this point will result in overow of the condensate drain. Slope the
drain pipe away at a minimum pitch of 1”for every 12 feet.
6. Attach a 1/4”water supply to the compression tting on the oat. The
water line must be connected to an uninterruptible supply. Fulton
recommends connecting it before the“Fast-Fill”valve to the boiler supply
but after the back ow preventer to avoid contamination of a potable
water supply. Maximum allowable water pressure to the compression
tting is 100 PSI.
Install pH Neutralization Kit
The pH Neutralization Kit is a Fulton-provided kit designed to bring the pH level
of the boiler’s condensate to a neutral level. It is not a replacement or alternative
for the Condensate Drain Trap. See Figure 8.
Adhere to the following for installation:
1. Use stainless or galvanized pipe and ttings to connect condensate drain
to kit.
2. Connect kit downstream of Condensate Drain Trap. See Figure 9.
3. Pipe outlet to appropriate drain.
NOTE:´Replacement bags are available from the Fulton Parts Department.
The medium in the container will neutralize the condensate of 12 MM Btu’s
for approximately 6 months.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
DO NOT USE GASOLINE, CRANKCASE
OIL OR ANY OIL CONTAINING
GASOLINE. If in doubt, contact
your Fulton representative prior to
operation.
Do not store or use gasoline or other
ammable vapors and liquids or
corrosive materials in the vicinity of
this or any other appliances. Cements
for plastic pipe should be kept away
from all sources of ignition. Proper
ventilation should be maintained to
reduce the hazard and to minimize
breathing of cement vapors.
Do not attempt to start boiler to test
wiring before lling and purging the
boiler. A dry re will seriously damage
the boiler and may result in property
damage or personnel injury and is
not covered by warranty.
4 CAUTION
The vent line connection on the gas
pressure regulator must be piped in
accordance with National Fuel Gas
code, latest addenda. In Canada, gas
installations must be in accordance
with current CAN/CGA, and/or local
codes.

Questions? Call(315) 298-5121,or visitus onlineat www.fulton.com
SECTION 2 PHW-IOM-2013-0214 INSTALLATION
2-13
FIGURE 8 - FULTON PH NEUTRALIZING KIT (WITHOUT PUMP)
FIGURE 9 - FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK
TOP VIEW
30 3/8
[771]
12 1/2
[318]
3 13/16
[97]
(TYP.)
FRONT VIEW
1 1/2" PLASTIC FITTING
CONNECTION TO DRAIN
1" NPT
CONNECTION
TO BOILER
10 3/4
[273]
11 1/4
[286]
ISOMETRIC VIEW

© The Fulton Companies 2013
INSTALLATION PHW-IOM-2013-0214 SECTION 2
2-14
Install Gas Piping
Adhere to the following for gas piping installation:
1. Gas Piping should be installed in accordance with
National Fuel Gas Code, ANSI Z223 1 1991 or latest
addenda and any other local codes which may apply.
In Canada gas installations must be in accordance with
the current CAN/CGA B149.1 and .2 and/or local codes.
2. The pipe and the ttings used should be new and free
of dirt or other deposits. Piping must be of the proper
size to insure adequate gas supply.
NOTE:´Do not use the boiler’s gas train inlet size as a
gauge for inlet piping size. Always refer to appropriate
gas piping charts.
NOTE:´Full port ball valves approved for gas should be
used for gas isolation to reduce pressure drop.
3. Gas pressure to inlet of gas train should be 7”WC for
natural gas and 11”WC for propane (PHW2000LE
requires 11”WC on natural gas). Connect gas supply
line to the open end of the tee on which the drip leg is
installed. See Figure 10.
4. When making gas piping joints, use a sealing
compound resistant to the action of liqueed
petroleum gases. Do not use Teon tape on gas line
threads.
5. 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.
6. The boiler must be isolated from the gas supply piping
system by closing its individual manual shut o valve
during any pressure testing of the gas supply system at
more than 1/2psi (3.5kPa).
7. Gas vents to outdoor air must be provided for the gas
pressure regulator. Restricting orices or bleed orices
should not be used at anytime. The vent line connection
on the gas pressure regulator must be piped to outdoor
air by installer in accordance with the National Fuel Gas
Code, ANSI Z223- 1-1991 or latest addenda.
8. In Canada gas installations must be in accordance with
the current CAN/CGA B149.1 and .2 and/or local codes.
}HONEYWELL PRESSURE SWITCH
The Honeywell C6097 pressure switch is designed with
internal vent limiters to meet UL 353 requirements and are
CSA certied, UL listed, FM approved, and CSD-1 acceptable.
Local codes may not permit a gas device (pressure switch)
without an external vent line connection. If that is the case, a
vent line must be added.
Install Field Wiring
Adhere to the following for eld wiring installation (see
Figures 11 and 52):
1. An independent power supply line is recommended
for the boiler. Connect one 120 volt (60Hz) fused power
line to terminal block to hot, or marked terminal per
electrical diagram. Connect applicable wires to neutral
and ground. Connect a ground wire to green colored
ground lug in electrical control box.
FIGURE 10 - GAS VALVE CONFIGURATION
FIGURE 11 - FIELD WIRING