FULTON PDWH750* General instructions

Fulton Gas Fired
Pulse Commercial
Water Heaters
Installation,
Operation And
Maintenance
Manual
December 2009
PDWH750*
PDWH1000

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 in a resonating system were issued before the end
of the 19th century.
Today... advanced pulse technology has finally found and
proven its way to the water heater industry. Fulton has
brought pulse combustion applications out of the residential
and light commercial application to larger commercial/industrial
heating uses.
Benefits of Gas Pulse Combustion:
Reliability
Flame sensing by pressure, no constant blower required.
Durability
These water heaters are constructed to ASME Code. The
design compensates for expansion and contraction which
cause other water heaters to eventually leak or fail.
No Expensive Chimney Needed
The pulse combustion system is self-venting through an
AL29-4C stainless steel vent. Sidewall venting does not
require a draft inducing fan.
Highest Efficiency Possible
Water heater efficiency is up to 99% depending on water
temperature.
Simple Reliable Spark Plug Ignition
No pilot or complex start sequence. Only a small assist
starting fan is required. Following ignition this is shut off so
there is no continuous electrical usage.
Gas and Pulse Combustion
Our country's most abundant natural resource...gas...
combined with modern-day pulse combustion is the cleanest
most efficient combination for commercial/industrial
applications today.
NOx (Nitrogen Oxides) commonly referred to as “smog” is a
prime contributor to acid rain. Environmental control agencies
are beginning to deal with this pollution problem. The Fulton
self-venting pulse combustion water heaters already meet or
exceed most new emission standards being set.
Fulton Pulse Water Heaters. . .The Modern
Approach to Commercial Water Heating

Contents
1
2
3
4
5
Section Safety Warnings
and Precautions-3
Installation-7
Operation-25
Maintenance-33
Parts and Warranty-37
1-PDWH

For Your Safety
Read Before Operating
WARNING: If you do not follow these
instructions exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
A. This water heater does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do not
try to light the burner by hand.
B. BEFORE OPERATING smell all around the
water heater area for gas. Be sure to smell
next to the floor because some gas is heavier
than air and will settle on the floor.
What To Do If You Smell Gas
• Do not try to light any appliance
• Do not touch any electric switch; do not
use any phone in your building.
• Immediately call your gas supplier,
call the fire department.
C. Use only your hand to push in or turn
the gas control knob. Never use tolls.
If the knob will not push in or turn by hand,
don’t try to repair it, call a qualified service
technician. Force or attempted repair may
result in a fire or explosion.
D. Do not use this water heater if any part has
been under water. Immediately call a
qualified service technician to inspect
the water heater and to replace any part of the
control system and any gas control which
has been under water.
Operating Instructions
1. STOP: Read theftey information above on
2-PDWH

Section 1Safety Warnings
and Precautions
3-PDWH

For Your Safety
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 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.
The following WARNINGS, CAUTIONS, and NOTES
appear in various sections of this manual. They are
repeated on these safety summary pages as an example and for emphasis.
WARNING
HOTTER WATER CAN SCALD: Water heaters are intended to
produce hot water. water heated to a temperature which will
satisfy clothes washing, dish washing, and other sanitizing
needs can scald and permanently injure you upon contact.
Some people are more likely to be permanently injured by hot
water than others. These include the elderly, children, the
infirm, or physically/mentally handicapped. If anyone using hot
water fits into one of these groups or if there is a local code or
state law requiring a certain temperature water at the hot water
tap, then you must take special precautions. In addition to
using the lowest possible temperature setting that satisfies your
hot water needs, some type of tempering device, such as a
mixing valve, should be used at the hot water taps used by
these people or at the hot water heater. Mixing valves are
available at plumbing supply or hardware stores. Follow
manufacturer’s instructions for installation of the valves. Before
changing the factory setting on the thermostat, read the
“Temperature Regulation” section in this manual.
CAUTION
Do not install the water heater in an uncontrolled environment
where the condensate will be subject to freezing temperatures.
Section 2.
NOTE
The water heater must not be installed on carpeting. Section 2.
NOTE
The water heater shall be installed such that the gas ignition
system components are protected from water
(dripping, spraying, rain, etc.) during water heater operation
and service. Section 2.
NOTE
All pulse combustion water heaters must be installed with
vibration isolators. No pulse combustion water heater shall be
lagged directly to the concrete floor due to the transfer of
vibration. In the box of trim shipped with each pulse water
heater, Fulton supplies 4 elastomer coated fiberglass cubes
used for vibration isolation. For all non-critical installations
these cubes must be under each foot of the water heater.
Flex connectors must be installed on the water inlet and outlet
lines. For installations near “sensitive” areas such as
offices, classrooms, or hospital rooms, spring mounts-
which fit under the corner of each water heater-must be
used instead of the cubes, and flex connectors must be
installed on the water inlet and outlet lines. Flex connectors
may be installed on the gas inlet if necessary. Spring loaded
pipe hangers may be used on the air inlet, water inlet and
outlet, and the flue gas outlet pipes, Contact your Fulton
Representative for vibration isolation packages designed
specifically for your application. Section 2.
CAUTION
The discharge from safety relief valve shall be so
arranged that there will be no danger of scalding of
personnel. Section 2.
WARNING
No shutoff of any kind shall be placed between the
safety relief valve and the water heater or on the discharge
pipe between such valve and the atmosphere. Doing so can
cause an accidental explosion from over-pressure. Section 2.
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 room into the water heater.
Section 2.
WARNING
HYDROGEN GAS: Hydrogen gas can be produced in a hot
water system that has not been used for a long period of time
(generally two weeks or more). Hydrogen gas is extremely
flammable and explosive. To prevent the possibility of injury
under these conditions, we recommend the hot water faucet be
opened for several minutes at the kitchen sink before any
electrical appliances which are connected to the hot water
system are used (such as a dish washer or washing machine).
If hydrogen gas is present, there will probably be an unusual
sound similar to air escaping from the pipe as the hot water
faucet is opened. There must be no smoking or open flame
near the faucet at the time it is open.
NOTE
See table on Page 13 for required pipe size, based on
overall length of pipe from meter plus equivalent
length of all fittings. Approximate sizing may be based
on 1 cubic foot of natural gas per 1,000 BTU/Hr.
input. Section 2.
NOTE
Piping schematic consistent with the ANSI/ASME
Boiler & Pressure Vessel Code Section IV. Section 2.
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.
4-PDWH

WARNING
Do not use matches, candles, flame or other sources
of ignition to check for gas leaks. Section 2.
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. Section 2.
WARNING
Do not attempt to start water heater to test wiring before filling
and purging the water heater. A dry-fire will seriously damage
the water heater and may result in property damage or
personnel injury and is not covered by warranty. Section 2.
NOTE
Solvent 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 solvent
vapors. Avoid contact of cement with skin and eyes.
Section 2.
NOTE
Time is critical at this stage. Do not allow primer to
dry before applying cement. Section 2.
NOTE
Assembly should be completed within 20 seconds
after last application of cement. Do not use hammer
to insert pipe. Section 2.
WARNING
Do not attempt to start water heater before filling and purging
water heater heating system. A dry fire will seriously damage
the water heater and may result in property damage or
personnel injury and is not covered by warranty. Section 2.
NOTE
The following purge procedure is applicable to the
recommended piping configuration only. See Figure
15. Section 2.
WARNING
This water heater shall not be connected to any heating
systems or component(s) previously used with a non-potable
water heating appliance.
If this water heater is also used for space heating applications,
all piping and components connected to the water heater shall
be suitable for use with potable water.
If a water heater is installed in a closed water supply system,
such as one having a back-flow preventer, check valve, water
meter with check valve, etc... in the cold water supply, means
shall be provided to control thermal expansion. Contact the
water supplier or plumbing contractor on how to control this
situation.
WARNING
Toxic chemicals such as used for treatment of boilers or non-
potable water heating appliances shall never be introduced into
a potable water space heating system.
WARNING
Never leave an opened manual air vent unattended.
In the event an opened vent is left unattended, water
damage could occur. Section 2.
NOTE
It is recommended that an authorized Fulton Pulse
start up agent make any required gas input adjustments.
Section 2.
WARNING
If you do not follow these instructions exactly a fire
or explosion may result causing property damage,
personnel injury, or loss of life. Section 3.
NOTE
Do not use this water heater if any part has been under water.
Immediately call a qualified service technician to inspect the
water heater and to replace any part of the control system
and/or gas control(s) which have been under water. Section 3.
NOTE
Prior to starting, make sure the procedure for purging
the heating system has been accomplished as detailed in
section 2. Section 3.
CAUTION
Should overheating occur or the gas supply fail to
shut off, shut off the gas supply at a location external
to the water heater. Section 3.
NOTE
If for any reason, the air intake or exhaust vent piping is
disassembled, re-assemble the piping in accordance with the
installation procedure outlined in the installation section of this
manual. Section 4.
NOTE
Your Fulton Pulse Combustion Hydronic Water heater has
been designed for years of trouble-free performance. To
ensure the continued safety and efficiency of the water heater,
the schedule of maintenance outlined in this section should be
adhered to. The water heater should be inspected annually. All
service should be performed by a certified contractor. Section 4.
WARNING
Keep water heater area clear and free from combustible
materials, gasoline and other flammable vapors and liquids.
Section 4.
NOTE
To prevent against untimely corrosion of hot and cold water
fittings, it is strongly recommended that di-electric unions or
couplings be installed on this water heater when connected to
copper pipe.
5-PDWH

6-PDWH
The following are copies of safety labels and warnings which are affixed
to the Fulton Pulse Water heaters. They are reproduced here as a further
safety precaution and as a reminder to quickly identify them on the water heater.
For Your Safety
Read Before Operating
WARNING: If you not follow these
instructions exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
Operating Instructions:
To Turn Off Gas To Water heater
A. This water heater does not have a pilot. It is
equipped with an ignition device which
automatically lights the burner. Do not
try to light the burner by hand.
B. BEFORE OPERATING smell all around the
water heater area for gas. Be sure to smell next
to the floor because some gas is heavier
than air and will settle on the floor.
What To Do If You Smell Gas
lDo not try to light any appliance.
lDo not touch any electric switch; do not
use any phone in your building.
lImmediately call your gas supplier from
a neighbor’s phone. Follow the gas sup-
plier’s instructions.
lIf you cannot reach your gas supplier,
call the fire department.
C. Use only your hand to push in or turn
the gas control knob. Never use tools.
If the knob will not push in or turn by hand,
don’t try to repair it, call a qualified service
technician. Force or attempted repair may
result in a fire or explosion.
D. Do not use this water heater if any part has
been under water. Immediately call a
qualified service technician to inspect
the water heater and to replace any part of the
control system and any gas control which
has been under water.
1. STOP: Read the safety information above on
this label.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to water heater.
4. This water heater is equipped with an ignition
device which automatically lights the
burner. Do not try to light the burner by hand.
5. Turn gas cock knob clockwise to OFF one
quarter turn.
6. Wait five (5) minutes to clear out any gas. Then
smell for gas, including near the floor. If you
smell gas, STOP! Follow “B” in the safety infor-
mation above on this label. If you don’t smell
gas, go to the next step.
7. Turn gas cock knob counterclockwise one
quarter turn to ON.
8. Turn on all electric power to the water heater.
9. Set the thermostat to the desired setting.
10. If the water heater will not operate, follow the
instructions “To Turn Off Gas To Water heater” and
call your service technician or gas supplier.
1. Set the thermostat to the lowest setting.
2. Turn off all electric power to the water heater if
service is to be performed.
3. Turn gas cock knob clockwise to OFF one
quarter turn.
Warning
Improper installation, adjustment,
alteration, service or maintenance can
cause injury or property damage. Refer to
the user’s information manual provided
with this water heater. For assistance or additional
information consult a qualified installer,
service agency or the gas supplier.
This Water heater Must
Be installed in accordance with local
codes, if any. If not, follow ANSI 223.1.
In Canada this water heater must be installed
in accordance with CAN/CGA B149.1 and .2
and/or local codes.
For Your Safety
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this water heater or any other appliance.
This Water heater Requires
A special venting system. Refer to installation
instructions section in Installation Manual
for roof or side wall venting methods and
necessary parts.
This Unit Must
Be installed at a minimum clearance of
1 inch or more (on either side) to any
combustible wall(s) and/or ceiling. This
unit shall be installed in a space larger
in comparison than the size of the water heater.

Section Installation
7-PDWH
2

Introduction
The Fulton Pulse water heater is an
automatic gas fired, direct vent water
heater. This water heater utilizes the pulse
combustion principle. It requires no
conventional burner controls, no pilot and
no flue or chimney. The combustion
components are of integral design with the
heat exchanger. For combustion, the water
heater uses 100% outside air supplied
through schedule 40 PVC pipe.
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. Each water heater
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 water heaters.
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 water heater, when installed,
must be electrically grounded in
accordance with the National eectrical
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 fired water
heaters, 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.
The following items
are standard trim
for Fulton Pulse
water heaters:
Full Modulation with a 5:1 turndown ratio
Fully Insulated
Microprocessor Based Control - 120 volt
Low Water Cutoff (Probe Type)
Control Panel Completely Wired with
Diagram
Operating Temperature Control
Hi-Limit Temperature Control w/ Manual
Reset
Air Pressure Switch
Spark Ignition
Main Motorized Gas Valve
Main Gas Pressure Regulator
Manual Lubricated Gas Cock
Second Gas Valve (Solenoid)
Included with and
packaged separately
with each water heater
are the following
components:
ASME Pressure Relief Valve
Pressure-Temperature Gauge
Air Intake and Exhaust Pipe Adaptors
Installation, Operation, and Maintenance
Manual
Elastomer Coated Fiberglass Cubes
Gas and Water Flex Connectors
Intake and Exhaust Mufflers
Optional Accessories
Condensate Liquid Drainer
Flex Connectors
Spring Mounts
Installation
General specifications and information about Fulton
Pulse Potable Water Heaters:
Models PDWH750 PDWH1000
BTU/HR. Input 750,000 1,000,000
BTU/HR Output* 660,000 880,000
Fuel NG/LPG NG/LPG
Approx. Dry Weight 1,800 lbs. 1,400 lbs.
Approx. Operating Weight 2,150 lbs. 2,150 lbs.
Floor Loading 300 lbs/ft2 300 lbs/ft2
Power Required 120/60/1 120/60/1
Min. Required 7" W.C.NG 7" W.C. NG
Gas Pressure 11" W.C. LPG 11" W.C. LPG
Max. Amp Draw (F L.A.) 4.0 4.0
MAWP 160 PSI 160 PSI
Water heater Width 27.5 IN 27.5 IN
Water heater Height 76 IN 76 IN
Water heater Depth 37.8 IN 37.8 IN
GPH @100°F
Temperature Rise 790 1055
Note: *Based on 40°F in -140°F out.
8-PDWH

Installation
90 Degree
Model No. Type Diameter/In. Length/Ft. Elbows
PDWH750 PVC 4 10 Minimum 0
4 35 Maximum 4
PDWH1000 PVC 4 10 Minimum 0
4 35 Maximum 4
Number of
90 Degree
Model No. Type Diameter/In. Length/Ft. Elbows
PDWH750 Stainless Steel 4 10 Minimum 0
4 35 Maximum 4
PDWH1000 Stainless Steel 4 10 Minimum 0
4 35 Maximum 4
Figure 1
9-PDWH
*Clearence from top
of water heater to
combustables must
be no less than 12”.
AIR INTAKE PIPING
Number of
EXHAUST VENT PIPING

Locating The Water
Heater:
The water heater should be located so
that the air supply and exhaust piping
between the water heater and outside
wall/roof are within the minimum and
maximum lengths for horizontal or
vertical venting. (Page 9) See Figure 1
for minimum clearances between the
water heater and any combustible
surfaces.
CAUTION
Do not install the water heater in an
uncontrolled environment where the
condensate will be subject to freezing
temperatures.
NOTE
The water heater must not be installed
on carpeting.
NOTE
The water heater shall be installed such
that the gas ignition system compo-
nents are protected from water
(dripping, spraying, rain, etc.) during
water heater operation and service.
NOTE
All Pulse water heaters must be
installed with vibration isolators. No
Pulse water heater shall be lagged
directly to the concrete floor due to the
transfer of vibration. In the box of trim
shipped with each pulse water heater,
Fulton supplies 4 elastomer coated
fiberglass cubes used for vibration
isolation. (Figure 2a) For all non-
critical installations these cubes
must be under each foot of the water
heater. White lines on blocks should be
in “up” position. Flex connectors must
be installed on the water inlet and outlet
lines. For installations near
“sensitive” areas such as offices,
classrooms, or hospital rooms,
spring mounts—which fit under the
comer of each water heater—must be
used instead of the cubes, and flex
connectors must be installed on the
water inlet and outlet lines. Flex
connectors must be installed on the gas
inlet. Spring loaded pipe hangers should
be used on the air inlet, water inlet and
outlet, and the flue gas outlet pipes.
Contact your Fulton Representative for
vibration isolation packages designed
specifically for your application.
Installing Spring
Isolation Mounts (Figure 2b)
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 water heater with
jacks or similar tools (Do not attempt to
raise the water heater via one (1) lifting
point, but lift evenly around the
perimeter of the boiler). Slide the spring
isolator under the water heater 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 finger tight.
5. Lower the water heater (evenly) onto
the spring isolators. Do not overload any
one isolator and take care not to push
the water heater 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 water heater is at
its height. When the water heater is
filled with water, the springs will
compress approximately 1-2".
8. Tighten the small cap screw, thus
securing the spring isolator to the sup-
ported equipment and locking the level-
ing bolt against turning.
9. Do not attempt to move the water
heater laterally while it is supported on
the isolators. If it is necessary to move
the water heater remove the weight
from the isolators by raising the water
heater 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.
Installing Seismic Spring
Isolation Mounts (Figure 2c)
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 water heater and
the housekeeping pad or structural floor.
If an operating clearance of other than
one inch is desired, use an appropriate
size shim.
5. Raise the water heater 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 water heater onto the
spring isolators taking care not to
overload any one isolator and taking
care not to push the water heater
sideways.
7. Install second washer and lock nut
one inch down from top of leveling bolt.
8. Grasp top of leveling bolt with vice
grip and turn leveling nut in a counter-
clockwise rotation until the water heater
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
water heater and locking the leveling
bolt against turning.
10. Do not attempt to move the isolators
laterally with the weight of the water
heater on them. If it is necessary to move
the boiler, remove the weight from the
isolators by raising the equipment before
moving.
Installation
Figure 2a
Figure 2b
Figure 2c
10-PDWH

Installing Water Heater
Trim
1. Each water heater is supplied with a
safety relief valve sized in accordance
with ASME requirements.The safety
relief valve shall be connected to the
coupling located in the top of the water
heater (Figure 3a). The safety relief
valve must be installed with a 6" nipple
between the water heater 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. CAUTION
The discharge from safety relief valve
shall be so arranged that there will be no
danger of scalding of personnel. When
the safety relief valve discharge is piped
away from the water heater 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
water heater or on the discharge pipe
between such valve and the
atmosphere. Doing so can cause an
accidental explosion from overpressure.
2. Each water heater is supplied with a
pressure-temperature gauge. A nipple is
installed in the water heater water outlet. A
tee is installed on the nipple. In the side
port of the tee the temperature gauge is
installed.
Installing Water Piping
1. The bottom connection to the water
heater is the INLET and must be used
for the return from the system.
2. The top connection on the water
heater is the OUTLET and must be
connected as the supply to the system.
3. Connect hot water supply to heating
system feed line.
4. Connect expansion tank.
5. Connect cold water supply to water
heater inlet connection.
6. Install expansion tank
7. Clearence from hot water pipes to
combustibles must be at least 6”.
8. The water heater is furnished with a
probe type low water cutoff. No field
piping is required. If the probe does not
sense water, the water heater will shut
down and a red indicator will be
illuminated on the control panel.
9. The water heater is not provided with
external drain connections. A drain
valve must be installed near the inlet
connection to the water heater and
piped to a suitable floor drain.
10. Before filling the water heater clean
and flush the system to remove any
debris. Clean and flush old piping
thoroughly before installing the water
heater. Consider installing a strainer
ahead of the water heater.
Installation
Figure 3a
11-PDWH

Condensate Drain Kit
The condensate drain kit is intended to be
utilized with any size pulse unit supplied
by Fulton. The 3/4” condensate drain on
the pulse unit will be connected to the 1”
inlet on the drain kit. One or more drain
lines may be connected to this inlet
(maximum of 8 total per drain kit) through
a common header.
An uninterruptable water supply is
required and shall be connected to the
1/4” compression fitting on the drain float.
The water supply maintains a water level
in the drain kit to prevent the flue gas
purge during startup or normal operation.
The 1-1/2” connection shall be piped to an
appropriate drain for disposal. If the water
supply must be temporarily disconnected,
the water heater(s) must be turned off to
prevent accidental flue gas emission in the
utility room.
The cover should be kept on at all
times, except during maintenance of the
drain. This drain should be monitored
and checked regularly in your pulse
maintenance schedule.
Model Part Number 4-57-000440
Recommended Operating Temp. 175oF max.
Capacity 4 QT
Inlet Size: 1”
Outlet Size 1-1/2”
Water Supply 1/4” COMP.
Max. units to attach to drain 8
Installing Condensate
Drain Piping
Figure 3b
A condensate collecting tank and
condensate pump will be required if an
in the floor drain is not available to
collect condensate (Collecting tank and
pump are not supplied with the water
heater). Complete condensate liquid
drainer kits are available from Fulton.
1. All piping must be galvanized, PVC or
stainless steel and should be free of
leaks.
2. Make sure either elastomer coated
fiberglass cubes or spring mounts have
been installed under each leg of the water
heater.
3. Install the condensate liquid drainer
to the condensate drain in the lower
right hand side of the water heater.
4. Connect 3/4" condensate drain(s),
maximum of 8 water heaters per drain
kit, to the 1"inlet at the base of the drain
tank. The bottom of the drain kit must be
a minimum of 5-1/2" lower than the
bottom of the exhaust decoupler when
connected in a manifold as shown in
Figure 3c, the manifold must be 51/2"
below c ondensate outlet and must
remain flooded.
5. Connect 11/2" drain outlet to an
appropriate waste line following
applicable codes. The 11/2" drain
connection on the drainer must be the
highest point prior to going to the drain.
Failure to keep drain piping lower than
this point will result in overflow of the
drainer. 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 fitting on the float. The
water line must be connected to an
uninterruptible supply. Fulton
recommends connecting it before the
“Fast-Fill” valve to the water heater
supply but after the back flow preventer
to avoid contamination of a potable
water supply. Maximum allowable water
pressure to the compression fitting is
100 PSI.
Installation
Figure 3b
12-PDWH
Figure 3c
IMPORTANT

Pipe Capacity For Natural Gas
Nominal Equivalent
Iron Pipe Internal Pipe Length
Size Diameter 90Þ Elbow Tee
Inches Inches Feet Feet 20 40 60 80 100 150 200
1.25 1.38 3.50 6.90 950 — — — — — —
1.50 1.61 4.00 8.00 1460 990 810 — — — —
2.00 2.07 5.20 10.30 2750 1900 1520 1300 1150 950 800
2.50 2.47 6.20 12.30 4350 3000 2400 2050 1850 1500 1280
3.00 3.07 7.70 15.30 7700 5300 4300 3700 3250 2650 22780
4.00 4.03 10.10 20.20 15800 10900 8800 7500 6700 5500 4600
Installing Gas Piping
Figure 4
NOTE
See the above chart for required pipe
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.
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 fittings used should
be new and free of dirt or other deposits
Piping must be of the proper size to
ensure adequate gas supply.
3. Gas pressure to inlet of gas train
should be 7" WC. for natural gas and
11" WC. for propane. Connect gas
supply line to the open end of the tee
on which the drip leg is installed.
4. When making gas piping joints, use
a sealing compound resistant to the
action of liquefied petroleum gases. Do
not use teflon tape on gas line threads.
5. After gas piping is completed and
before wiring installation is started,
carefully check all piping connections,
(factory and field), for gas leaks. Use a
soap and water solution.
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.
6. The water heater must be
disconnected at the water heater shut
off valve from the gas supply piping
system during any pressure testing of
the system at pressure in excess of 1/2
psig (14" WC)(3.5 kPa).
7.The water heater must be isolated
from the gas supply piping system by
closing its individual manual shut off
valve during any pressure testing of the
gas supply system at test pressures
equal or less than 1/2psi (3.5kPa).
8. Gas vents to outdoor air must be
provided for the pressure regulator and
gas pressure switches. Restricting
orifices or bleed orifices should not be
used at anytime.
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.
Installation
Figure 4
Maximum Capacity in Cubic Feet of Natural Gas Per Hour
Pressure Drop of 0.5" W.C.
Equivalent Length of Pipe in Feet
13-PDWH
CANADA
US

Installing Field Wiring
Figure 5
It is recommended that an independent
power supply line be provided for the
water heater. Connect one 120 volt
(60Hz) fused powerline to terminal block
as shown in Figure 5a. Connect
applicable wires to neutral and ground.
Connect a ground wire to green colored
ground lug in electrical control box.
WARNING
Do not attempt to start water heater to
test wiring before filling and purging the
water heater. A dry fire will seriously
damage the water heater 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.
Installation
Electrical Schematic
NOTE
Consult factory for custom control applications.
Figure 5a
14-PDWH
Figure 5

Installation
Figure 5b
Sequence of Operation
1. Turn on main breaker.
2. Low water safety relay (LWSR) is
energized when the main breaker is
turned on. (Red light on the water
heater panel is lit and if the optional
alarm is provided, alarm will go off.
Current is not allowed to pass to the
high limit temperature control until a)
the probe in the water heater shell
senses the water and b) the manual
reset switch is reset. If a and b are
both satisfied, the red light is turned
off.
3. High limit temperature control allows
current to pass to the next control if
the temperature in the water heater
water is not causing the control to
open the circuit.
4. Burner switch is then closed to ener-
gize the operating temperature con-
trol. (Green light on the panel is lit).
5. Operating temperature control
allows current to pass to the auto-
matic control relay if the temperature
of the water is not causing the
control to open the circuit.
6. 120V power is input to the automatic
control relay (RM7865A).
7. Purge blower is energized for 35
seconds.
8. Purge fan switch is made, signaling
the control to proceed.
9. Spark plug is energized.
10. Gas valve is energized.
11. Pressure sensing switch is made
(proof of flame) allowing sequence
to continue.
12. Pulse combustion will continue
until one or more of the following
things happen:
A. Operating temperature control is
satisfied.
B. High limit temperature control is
satisfied.
C. Low water safety relay loses
water on probe.
D. Burner switch is turned off.
E. Main breaker is turned off.
Glossary
AC — Audible Alarm Control
(Optional)
ACR — Automatic Control Relay
(7800 series)
BM — Purge Fan Motor
BS — Burner Switch
CR — Control Relay
HLTC — Hi Limit Temp. Control
LW — Panel Light (Low Water
Indicator)
LWCP — Low Water Cutoff Probe
LWRS — Low Water Reset Switch
LWSR — Low Water Safety Relay
GV — Main Gas Valve
OTC — Operating Temp. Control
PFS — Purge Fan Switch
PL — Panel Light (Power On Green)
PSS — Pressure Sensor Switch No. 2
RC — Relay Coil
SP — Spark Generator
S.P. — Spark Plug
TB-H — Terminal Block (Hot)
TB-N — Terminal Block (Neutral)
15-PDWH

Air supply is on the top. See Figure 6.
For Models PDWH750 & PDWH1000,
the connections are 4" NPT thread female
fittings. These fittings will accept 3" and
4" male/female pipe to tubing adaptors
respectively. This line must be sloped
down toward the unit with a pitch of at
least 1/4" per foot. Failure to do so can
result in a condensate pocket which can
result in an inoperative water heater. A
high spot is acceptable, provided the
pitch from the high spot is maintained
back to the water heater and to the
outside point of air intake.
The air intake must be piped out of the
building. Air Intake pipes and fittings for
all models shall be Schedule 40 PVC
pipe. All Schedule 40 PVC pipe, fittings,
primer and solvent cement must
conform with American National
Standard Institute and the American
Society for Testing and Materials
(ANSI/ASTM standards.)
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 water heater
room into the water heater. The solvent
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
Solvent 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 solvent vapors. Avoid
contact of cement with skin and eyes.
The following procedure for cementing
joints (per ASTM D2855) should be
adhered to:
Step 1
Measure and cut PVC pipe to desired
Iength.
Step 2
Chamfer end of pipe, removing any
ridges or rough edges. If end is not
chamfered, the edge of the pipe may
remove cement from the fitting socket
and result in a leaking joint.
Step 3
Clean and dry surfaces to be joined.
Step 4
Test fit joint and mark depth of fitting on
pipe outside.
Step 5
Uniformly apply liberal coat of primer to
inside socket surface of fitting and male
end of pipe to depth of fitting socket.
Step 6
Promptly apply solvent cement to end of
pipe and inside socket surface of fitting.
Cement should be applied lightly—but
uniformly—to inside of socket. Take
care to keep excess cement out of
socket. Apply second coat to pipe end.
NOTE
Time is critical at this stage. Do not allow
primer to dry before applying cement.
Step 7
Immediately after applying last coat of
cement to pipe, while inside socket sur-
face and end of pipe are wet with cement,
insert end of pipe into socket, turn pipe 1/4
turn to distribute cement evenly, continue
to insert pipe until it bottoms out.
NOTE
Assembly should be completed within
20 seconds after last application of cem-
ent. Do not use hammer to insert pipe.
Step 8
After assembly, wipe excess cement
from pipe at end of fitting socket. A
properly made joint will show a bead
around its entire perimeter. Any gaps
may indicate a defective assembly due
to insufficient cement.
Step 9
Handle joints carefully until completely set.
Intake Muffler
Installation - Figure 7
Follow steps 1-9 above for cementing
joints. For best noise attenuation, the
muffler should be installed as close to
the water heater as possible.
Installation
Figure 6
Air Intake Supply Piping
Installation Preparation
The water heater is equipped with air
intake supply and exhaust vent
connections located at the top and rear
of the water heater.
16-PDWH
Air Intake
Water Heater
Connection
Pipe-to-Tubing
Adapter
Schedule
40 PVC Pipe

Installation
17-PDWH
Exhaust Vent Piping
Installation
Preparation
NOTE: A Fulton PDWH water heater
should not be connected to a common
venting system with other types of gas
appliances.
The water heater is equipped with an
exhaust vent connection located at the
rear of the water heater. (Figure 6) For
Models PDWH750 & PDWH1000 the
connections are 4" NPT threaded
female fittings.
The exhaust line must be sloped
down toward the unit with a pitch
of at least 1/4" per foot. Failure to
do so can result in a condensate
pocket which can result in an
inoperative water heater. There must
be no low spots in the exhaust pipe, as
this can also result in a condensate
pocket. A high spot is acceptable,
provided the pitch from the high spot is
maintained back to the water heater to
the outside point of the exhaust. In
supporting piping, or routing it
through a rafter or wall, always use
vibration eliminating hangers around
the piping to prevent transmission of
pulsations. Always avoid rigid
connections between piping and
structural members of the building. Flue
exhaust pipes and fittings for all models
shall be stainless steel. The stainless
steel shall be UL temperature rated at
minimum air clearance to combustibles.
At 480° F temperature rating, a 5"
minimum air space clearance to
combustibles is required. Fulton pulse
combustion hydronic heating water
heaters require a special venting
system. Applicable Federal Codes are
NFPA 54/ANSI Z223.1 National Fuel
Gas Code and NFPA/ANSI 211
Chimneys, Fireplaces, Vents, and Solid
Fuel Burning Appliances. In Canada
refer to the venting section of CAN/CGA
B149.1 and .2. These codes contain
information on special gas vents. The
gas vent installer should be familiar with
these Federal Codes as well as local
codes and regulations.
The procedure for adhesive joining
stainless steel pipe and fittings follows:
Step 1
Do not mix stainless steel pipe with
galvanized or other alternatives for the
entire length of the system.
Step 2
All joints between sections of the vent
connector and the vertical conduit must
be sealed with a high temperature
sealant to prevent any possible leakage
of flue gas.
Step 3
Apply a bead of sealant, about 1/4inch in
diameter, completely around the male
(without tabs) end of each conduit
section or elbow, between 1/4and 3/8
inch from the end of the section. Also
run a similar sized bead down the seam
weld of each section, from the edge of
the pipe to the top of the bulge.
Step 4
Fully insert the male end of the section
into the female fitting of the section
below. Spread any sealant that squeezes
out around the circumference of the
joint. Attach the sections together
with the locking ring and tabs. Again
spread any extruded sealant around the
joint. Inspect the joint to ensure that flue
gases will not escape. If necessary,
apply additional sealant to any voids.
Allow the sealant 24 hours to cure
before operating the water heater.
Step 5
All pipes, elbows, and fittings used in
condensate piping from liquid drain to
floor drain shall be high temperature
plastic or stainless steel.
Exhaust Muffler
Installation
Follow steps 1-5 above to join the fittings.
For muffler drain installation:
1. For mufflers installed in the vertical
configuration the drain can be plugged.
2. For mufflers installed in the horizontal
configuration, the drain should be piped
to the drain line between the water heater
and the liquid drainer.
For best noise attenuation, the muffler
should be installed as close to the water
heater as possible.

Installation
Typical Ceiling and Roof Penetration Detail
18-PDWH
Figure 8
Air Intake Supply and
Exhaust Vent
Installation
Air intake supply and exhaust vent
pipes and fittings are suitable for
vertical, through-the-roof or horizontal
through-the-wall installation. The vent
system must be installed in accordance
with the manufacturer’s instructions.
All vent pipes and fittings must be
installed with appropriate air space
clearances to combustibles. These
air space clearances apply to indoor
or outdoor vents—whether they are
open, enclosed, horizontal or vertical
or pass through floors, walls, roofs, or
framed spaces. See Figure 8. The air
space clearances should be observed
to joists, studs, subfloors, plywood,
drywall or plaster enclosures, insulating
sheathing, rafters, roofing, and any
other material classed as combustible.
The required minimum air space
clearances also apply to electrical
wires and any kind of building insulation
away from gas vent and out of the
required air space clearance.
Vertical runs or vent pipes and fittings
passing through floors, ceilings, or in
framed walls must be fire stopped at floors
and ceilings. The fire stop must close in
the area between the outside of the vent
and the opening in the structure. Figure 9.
When passing through a floor or ceiling,
frame in an opening providing 5" or 9" air
space clearance to vent pipe as
applicable. The fire stop fits to the bottom
of a framed opening 131/4" square. Nail
into the inside of the framed opening