FULTON PulseHW Series User manual

Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713
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Fulton PulseHW
Gas Pulse Combustion
Hydronic Heating Boilers
Installation, Operation and Maintenance Manual
Fulton Heating Solutions, Inc.
972 Centerville Road
Pulaski, NY 13142
Telephone: [phone]
Facsimile: [phone]
www.fulton.com
Serial # __________________________
Model # __________________________
Fulton Order # __________________________
Sold To __________________________
Job Name __________________________
Date __________________________

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Table of Contents
Introduction
Section 1 – Safety Warnings &
Precautions
Section 2 – Installation
1. General Specifications
2. Introduction
3. Standard Trim
4. Components Included
5. Accessories
6. Locating the Boiler
7. Installing Elastomer Cube Isolation
Mounts
8. Installing Spring Isolation Mounts
9. Installing Seismic Spring Isolation
Mounts
10. Installing Boiler Trim
11. Installing Water Piping
12. Condensate Drain Kit
13. Installing Condensate Drain Piping
14. Installing Gas Piping
15. Installing Field Wiring
16. Sequence of Operation
17. Air Intake Supply Piping Installation
Preparation
18. Intake Muffler Installation
19. Exhaust Vent Piping Installation
Preparation
20. Exhaust Muffler Installation
21. Air Intake & Exhaust Piping
Requirements for the Pulse Boiler
22. Air Intake Supply and Exhaust Vent
Installation
23. Vertical Vent Flashing and Installation
24. Vertical Vent Termination
25. Horizontal Installation Wall Penetrations
26. Wall Thimble Installation
27. Horizontal Vent Termination
28. After Installation/Prior to Start-Up
29. Installation Checkpoints
30. Testing Ignition Safety Shut Off
31. Measure Gas Flow Rate
32. To Correct Input
33. Rating the Boiler
34. To Check for High Gas Pressure
35. For High Gas Pressure Installations
36. Before Leaving the Installation
Section 3 – Operation
1. Before Operating Your Boiler
2. Starting the Boiler
3. If the Boiler doesn’t start
4. Sequence of Operation
5. Sequence of Operation for Modulated
Pulse Hydronic Boilers
6. Programming Instructions for Yokogawa
UT320 Standard program
7. Worksheets
8. Advanced Programming Features
9. Siemens RWF40 Control
10. Linkage Adjustment for Pulse Modulated
Boilers
(continued on next page)

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Section 4 – Maintenance
1. Before Each Heating Session
2. Recommended Monthly Maintenance
3. Recommended Annual Maintenance
4. Troubleshooting
5. Troubleshooting-Fault Code Diagnosis
6. Troubleshooting-RM7865C without display
7. Honeywell RM7865C
Section 5 – Parts & Warranty

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Fulton Pulse Combustion Hydronic Boilers…The Modern Approach to
Commercial Heating
The application of the Pulse combustion principle
illustrates how fresh perceptions and changing needs
can breathe new life into an old idea. The oldest
patents related to this method of burning fuel in a
resonating system were issued before the end of the
19th century. Today...advanced Pulse technology has
finally found and proven its way into the heating boiler
industry.
Fulton has brought Pulse combustion applications out
of the residential and light commercial markets into
larger industrial/commercial heating uses.
Benefits of Gas Pulse Combustion:
Reliability
Flame sensing by pressure switches and flame rod, no
constant blower required.
Durability
These new boilers are constructed to ASME Code. The
design compensates for expansion and contraction,
which cause other boilers to eventually leak or fail.
No Expensive Chimney Needed
Pulse combustion is self-venting through an AL29-4C
stainless steel vent. Sidewall venting does not require a
draft-inducing fan.
Highest Efficiency Possible
Boiler efficiency is up to 98% depending on return water
temperature and firing rate.
Simple Reliable Ignition
No pilot or complex start sequence. Only a small assist
fan is required. Following ignition this assist fan is shut
off, so there is no continuous blower motor electrical
usage.
Low NOx Emissions
Our country's most abundant natural resource...natural
gas...combined with modern-day pulse combustion is
the cleanest most efficient combination for
industrial/commercial applications today.
NOx (Nitrogen Oxide) commonly referred to as “smog”
is a prime contributor to acid rain. Environmental control
agencies are beginning to deal with this pollution
problem. Fulton Pulse combustion hydronic heating
boilers already meet or exceed most new emission
standards.

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Section 1

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Section 1 – Safety Warnings & Precautions
This manual is provided as a guide to the correct operation and maintenance of your Fulton PulseHW
Boiler, and should be permanently available to the staff responsible for the operation of the boiler.
These instructions must not be considered as a complete code of practice, nor should they replace
existing codes or standards which may be applicable.
The requirements and instructions contained in this section generally relate to the standard Fulton
PulseHW Boiler. When installing a packaged unit, this entire section should be read to ensure that the
installation work is carried out correctly.
Prior to shipment the following tests are made to assure the customer the highest standards of
manufacturing:
a) Material inspections
b) Manufacturing process inspections
c) ASME welding inspection
d) ASME hydrostatic test inspection
e) Electrical components inspection
f) Operating test
g) Final engineering inspection
h) Crating inspection
All units are crated for forklift transport. Once uncrated, all units can be transported with a forklift. Under
no circumstances should weight be allowed to bear on the jacket, control panel, or fan housing of any
Fulton Boiler.
Rigging your boiler into position should be handled by a competent rigger experienced in handling heavy
equipment.
The customer should examine the boiler for any damage. It is the responsibility of the installer to
ensure all parts supplied with the boiler are fitted in a correct and safe manner.
The installation of the Fulton PulseHW Boiler should be carried out by competent personnel in
accordance with all applicable local codes. All state and jurisdictional codes beyond the scope of the
applicable ASME Boiler and Pressure Vessel Codes, for its corresponding classification, should be
followed in all cases. Jurisdictional authorities must be consulted prior to installation.

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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 modifications. Unapproved modifications can cause injury and damage. Contact your
Fulton dealer before modifying the boiler.
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.
Do not attempt repairs or any other maintenance work you do not understand. Obtain a Service
Manual from Fulton or call a Fulton Service Engineer.
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result
causing property damage, personal injury or loss of life.
- Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other
appliances.
- WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s
instructions.
If you cannot reach your gas supplier, call the fire department.
- Installation and service must be performed by a qualified installer, service agency or the gas supplier.
For Your Safety
The following WARNINGS, CAUTIONS and NOTES appear in various chapters of this manual. They are
repeated on these safety summary pages as an example and for emphasis.
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.

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It is the responsibility and duty of all personnel involved in the operating 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.
Note
The Fulton Pulse combustion hydronic heating boiler is not designed for use in systems where
water is replenished. Mineral buildup can occur on the heat transfer surfaces and result in over
heating and possible failure of the heat exchanger.
Caution
Do not install the boiler in an uncontrolled environment where the condensate will be subject to
freezing temperatures.
Note
The boiler must not be installed on carpeting.
Note
The boiler shall be installed such that the gas ignition system components are protected from
water (dripping, spraying, rain, etc.) during boiler operation and service.
Note
All pulse combustion boilers must be installed with vibration isolators. No pulse combustion
boiler shall be lagged directly to the concrete floor due to the transfer of vibration. In the box of
trim shipped with each pulse boiler, Fulton supplies 4 elastomer coated fiberglass cubes used for
vibration isolation. For all non-critical installations these 3" x 3" x 2" cubes must be under each
foot of the boiler. Flex connectors must be installed on the water inlet and outlet lines. For
installations near noise “sensitive” areas such as offices, classrooms, or hospital rooms, spring
mounts, which fit under the corner of each boiler, must be used instead of the cubes. Flex
connectors must be installed on the gas supply water inlet and water outlet lines. Spring loaded
pipe hangers may be used on the air inlet, water inlet and outlet, and the flue gas vent. Contact
your Fulton Representative for vibration isolation packages designed specifically for your
application.

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Caution
The discharge from safety relief valve shall be so arranged that there will be no danger of scalding
personnel. When the safety relief valve discharge is piped away from the boiler to the point of
discharge, there shall be provisions made for properly draining the piping.
Warning
No shutoff of any kind shall be placed between the safety relief valve and the boiler or on the
discharge pipe between such valve and the atmosphere. Doing so can cause an accidental
explosion from overpressure.
Note
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 coiIs, located in air handling units
where they may be exposed to refrigerated air circulation, such boiler piping systems shall be
equipped with flow control valves or other automatic means to prevent gravity circulation of the
boiler water during the cooling cycle.
Note
See the above chart for required gas line size, based on overall Iength of pipe from meter plus
equivalent length of all fittings. Approximate sizing may be based on 1,000 BTU for 1 cubic foot of
natural gas.
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.
Warning
Do not use matches, candles, flame or other sources of ignition to check for gas Ieaks.
Note
The vent line connection on the gas pressure regulator and the low and high gas pressure
switches must be piped to outdoor air by installer in accordance with the National Fuel Gas Code,
ANSI Z223- 1-1991 or latest addenda.
In Canada gas installations must be in accordance with the current CAN/CGA B149.1 and .2 and/or
local codes.

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Note
High/Low Gas Pressure Switch: Low pressure switch should not be set less than 50% of manifold
pressure. High pressure switch should not be set any more than 150% of the manifold pressure.
Warning
Do not attempt to start boiler to test wiring before filling and purging the boiler. A dry fire will
seriously damage the boiler and may result in property damage or personnel injury and is not
covered by warranty.
Caution
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after servicing.
Note
Intake PVC piping must be assembled using cement. This will ensure that the intake is air tight
and will not allow contaminates from the boiler room into the boiler. The cement shall be free
flowing and contain no lumps, undissolved particles or any foreign matter that adversely affects
the joint strength or chemical resistance of the cement. The cement shall not show gelation,
stratification, or separation that cannot be removed by stirring.
Warning
Cements for plastic pipe are flammable 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.
Note
Time is critical at this stage. Do not allow primer to dry before applying cement.
Note
Assembly should be completed within 20 seconds after last application of cement. Do not use
hammer to insert pipe.
Note
A Fulton Pulse boiler should not be connected to a common venting system with other types of
gas appliances.

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Warning
Do not attempt to start boiler before filling and purging boiler heating system. A dry fire will
seriously damage the boiler and may result in property damage or personnel injury and is not
covered by warranty.
Warning
Never leave an opened manual air vent unattended. In the event an opened vent is left unattended,
water damage can occur.
Warning
If you do not follow these instructions exactly, a fire or explosion may result causing property
damage, personal injury, or loss of life.
Note
DO NOT use this boiler if any part has been under water. Immediately call a qualified service
technician to inspect the boiler and to replace any part of the control system and/or gas control(s)
which has been under water.
Note
Prior to starting, make sure the procedure for purging the heating system has been accomplished
as detailed in Section 2.
Caution
Should overheating occur or the gas supply fail to shut off, shut off the gas supply at a location
external to the boiler.
Note
Do not change the Flame Pressure Switch settings.
Note
A series of relays are used in the above sequence of operation. Please refer to the wiring diagram
for details.
Note
It is important to know that if the following parameters are altered, the entire set of factory values
will be altered: (In) or (UNIT) located in the Input/Output Menu; (AL1) in the Functional Parameters
Menu; (A1) in the Operating Parameters Menu.

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Note
If the rh (Range High) value has been changed in the Input/Output Menu, the Setpoint Temperature
will read zero (0) after return from the menus. Simply press the Up Arrow key until the desired
setpoint value is shown. Hit SET/ENT once to store and begin operation.
Note
At high fire, the gas butterfly valve will be full open in the horizontal position. Exhaust butterfly
valve will be full open in the vertical position.
Note
The unit will still shut off at setpoint plus 5°F (standard settings). Also, being in manual mode, the
temperature control ignores any PID or auto tune settings.
Note
Your Fulton Pulse Combustion Hydronic Boiler has been designed for years of trouble-free
performance. To ensure the continued safety and efficiency of the boiler, the schedule of
maintenance outlined in this section should be adhered to. The boiler should be inspected
annually. All service should be performed by a certified contractor.
Warning
Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors
and liquids.
Note
If for any reason, the air intake or exhaust vent piping is disassembled, reassemble the piping in
accordance with the installation procedure outlined in the installation section of this manual.
Note
Should you suspect that the boilers flue passage ways have become blocked, contact your
recognized Fulton representative.
Note
On models PHW300 through PHW1400 the spark plug is located in the top of the boiler. In
PHW2000 the spark plug is located in the gas injector behind the air flapper, and requires a spark
plug removal tool.

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The following are copies of safety labels and warnings, which are affixed to the Fulton Pulse
Combustion Hydronic Boilers. They are reproduced here as a further safety precaution and as a
reminder to quickly identify them on the boiler.

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Section 2

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Section 2 – Installation
1. General Specifications and Information about Fulton Pulse Combustion
Commercial/Industrial Hydronic Boilers
Models PHW300 PHW500 PHW750 PHW1000 PHW1400 PHW2000
BTU/HR. Input 300,000 500,000 750,000 1,000,000 1,400,000
2,000,000 NG
1,800,000 LPG
Fuel NG/LPG NG/LPG NG/LPG NG/LPG NG/LPG NG/LPG
Approx. Dry Weight 1,395 lbs. 1,395 lbs. 2,275 lbs. 2,275 lbs. 2,970 lbs. 3,785 lbs.
Approx. Operating
Weight 1,680 lbs. 1,680 lbs. 2,625 lbs. 2,625 lbs. 3,635 lbs. 4,385 lbs.
Floor Loading 235 lbs/ft2235 lbs/ft2270 lbs/ft2270 lbs/ft2240 lbs/ft2250 lbs/ft2
Power Required 120/60/1 120/60/1 120/60/1 120/60/1 120/60/1 120/60/1
Min. Required Gas
Pressure
7”W.C.NG
11” W.C. LPG
7”W.C.NG
11” W.C. LPG
7”W.C.NG
11” W.C. LPG
7”W.C.NG
11” W.C. LPG
7”W.C.NG
11” W.C. LPG
7”W.C.NG
11” W.C. LPG
Max. Amp Draw
(FLA) 4.2 4.2 4.2 4.2 4.2 10.0
MAWP 60/160 PSI 60/160 PSI 60/160 PSI 60/160 PSI 60/160 PSI 60/160 PSI
Boiler Width 27.5 IN 27.5 IN 27.5 IN 33.6 IN 33.6 IN 33.6 IN
Boiler Height 64 IN 64 IN 76 IN 76 IN 81 IN 81 IN
Boiler Depth 37.8 IN 37.8 IN 50.8 IN 50.8 IN 65 IN 75.8 IN
2. Introduction
a) The Fulton Pulse combustion hydronic boiler is an automatic gas fired, direct vent boiler.
This boiler utilizes pulse combustion principle. It requires no conventional burner controls,
no pilot and no chimney. The combustion components are of integral design with the heat
exchanger. For combustion, the boiler uses 100% outside air supplied through schedule
40 PVC pipe or can be vented conventionally. The products of combustion are vented
outdoors through non-corrosive venting materials which will withstand 480°F (249°C)
temperatures. These pipes can be routed either through a roof or through the side wall of
a building.
b) Each boiler is built to ASME and CSD-1 Codes, hydrostatically tested, test fired, and
shipped as a complete packaged unit. Gas, water, and electrical connections are similar
to conventional boilers.
c) 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.

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d) 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.
e) 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 fired 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.
3. The following items are standard trim for Fulton Pulse Combustion
Hydronic Boilers:
a) Fully Insulated
b) Microprocessor Based Control - 120 volt
c) Low Water Cutoff (Probe Type)
d) Control Panel Completely Wired with Diagram
e) Operating Temperature Control
f) Hi-Limit Temperature Control w/ Manual Reset
g) Air Pressure Switches
h) Spark Ignition
i) Main Motorized Gas Valve
j) Main Gas Pressure Regulator
k) Manual Lubricated Gas Cock
l) Second Gas Valve (Solenoid)
m) Flame Rod
4. Included with and packaged separately with each boiler are the following
components:
a) ASME Pressure Relief Valve
b) Pressure-Temperature Gauge
c) Air Intake and Exhaust Pipe Adaptors
d) Installation, Operation, and Maintenance Manual
e) Elastomer Coated Fiberglass Cubes
f) Gas and Water Flex Connectors (for Models PHW750, 950, 1000, 1400 & 2000)
g) Intake and Exhaust Mufflers (for Models PHW750, 950, 1000, 1400 & 2000)
h) 1 Can Touch-up Paint