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
TABLE OF CONTENTS PHW-IOM-2013-0214 Introduction 1-1 Operation 3-1 Overview .............................................................................................................. 1-2 Warnings & Cautions............................................................................................ 1-2 Disclaimers and Local Codes ................................................................................ 1-2 Before Start Up......................................................................
TABLE OF CONTENTS 0-2 PHW-IOM-2013-0214 © The Fulton Companies 2013
INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.
INTRODUCTION PHW-IOM-2013-0214 SECTION 1 Overview Warnings & Cautions Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers: 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. § Material inspections § WARNINGS must be observed to prevent serious injury or death to personnel.
INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.
INSTALLATION ! 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 certified for indoor installation only. This boiler is not designed for use in systems where water is continuously replenished.
SECTION 2 } 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 Cutoff (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
INSTALLATION PHW-IOM-2013-0214 SECTION 2 TABLE 1 - BOILER DIMENSIONS AND OPERATING REQUIREMENTS Model PHW 300 500 750 1000 1400 2000 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.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 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.
INSTALLATION ! PHW-IOM-2013-0214 SECTION 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 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.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 ! 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. FIGURE 4 - INSTALLING SPRING ISOLATION MOUNTS ´ NOTE: Do not attempt to move the boiler laterally while it is supported on the isolators.
INSTALLATION ! PHW-IOM-2013-0214 SECTION 2 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 shutoff 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.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 § 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. § 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.
INSTALLATION ! 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, flame 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 off to prevent accidental flue gas emission into the boiler room.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 the cooling cycle. 14. The boiler is furnished with a probe type low water cutoff. No field 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 floor drain. A Boiler Drain Assembly can also be purchased from Fulton.
INSTALLATION ! 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.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 FIGURE 8 - FULTON PH NEUTRALIZING KIT (WITHOUT PUMP) 30 3/8 [771] 3 13/16 [97] (TYP.) 12 1/2 [318] TOP VIEW 10 3/4 [273] 11 1/4 [286] ISOMETRIC VIEW 1" NPT CONNECTION TO BOILER 1 1/2" PLASTIC FITTING CONNECTION TO DRAIN FRONT VIEW FIGURE 9 - FIELD CONNECTIONS FOR CONDENSATE DRAIN TO PH NEUTRALIZATION TANK Questions? Call (315) 298-5121, or visit us online at www.fulton.
INSTALLATION PHW-IOM-2013-0214 SECTION 2 FIGURE 10 - GAS VALVE CONFIGURATION FIGURE 11 - FIELD WIRING 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.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 2. Ensure gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service. 3. Any attempt to start the boiler to test wiring prior to filling and purging may result in a dry fire and void the warranty. Air Intake Supply Piping Installation Preparation The boiler is equipped with air intake supply and exhaust vent connections located at the top and rear of the boiler respectively. See Figure 12.
INSTALLATION 4 CAUTION Intake PVC piping must be assembled using cement. This ensures that the intake is air tight and will not allow contaminants to enter the boiler from the boiler room. Cement must 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 must show no gelation, stratification, or separation that cannot be removed by stirring.
SECTION 2 5. Uniformly apply liberal coat of primer to inside socket surface of fitting and male end of pipe to depth of fitting socket. 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. Time is critical at this stage. Do not allow primer to dry before applying cement. 7.
INSTALLATION ! WARNING Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose significant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 Air Intake & Exhaust Piping Requirements for the Pulse Boiler Adhere to the following for air intake and exhaust piping: 1. Use piping that matches the inlet/outlet connection sizes for the first 35 feet and 4 elbows closest to the boiler. See Tables 2 and 3.
INSTALLATION ! PHW-IOM-2013-0214 TABLE 3 - EXHAUST VENT PIPING REQUIREMENTS 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. Operating the boiler beyond its design limits is dangerous and may also cause boiler damage. Do not attempt to upgrade boiler performance with unapproved modifications.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 5. Pass the vent pipe through the opening in the fire stop. If used as a support, install the support ring around the vent pipe above the fire stop. Slide the support ring down to the top of the fire stop and tighten it securely to the vent pipe. Firestop supports can support up to 10 feet of vent pipes and are recommended at all floor and ceiling penetrations. Figure 16. Air intake supply and exhaust vent pipes and fittings must be securely supported.
INSTALLATION PHW-IOM-2013-0214 4FT / 122 CM ( } 3 IN. / 7.62 CM ) SECTION 2 NOTE: AIR INTAKE AND EXHAUST TERMINATION SHOULD BE SEPERATED AS FAR AS POSSIBLE TO PREVENT FLUE GAS RECIRCULATION DURING DIFFERENT WIND CONDITIONS. NOTE: STACK SHOWN IS FOR REFERENCE PURPOSES ONLY. OTHER CONFIGURATIONS MAY BE ACCEPTABLE. MIN 4FT / 122 CM ABOVE AIR INTAKE PIPING SCREENED INLET EXHAUST STACK IS DOWNWIND OF AIR INTAKE OPENING ADHESIVE SEAL IF SNOW ACCUMULATION IS APPLICABLE, OPENING TO BE 1 FT. / 30 CM ( MIN.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 FIGURE 15 - FIRE STOPPING REQUIRED FOR ALL CEILING/FLOOR INSTALLATIONS FIGURE 17 - CORRECT ROOF FLASHING INSTALLATION FIGURE 16 - FIRE STOPPING Questions? Call (315) 298-5121, or visit us online at www.fulton.
INSTALLATION PHW-IOM-2013-0214 SECTION 2 FIGURE 18 - ROOF PITCH Horizontal Installation Wall Penetrations Wall Thimble Installation Adhere to the following for horizontal wall penetrations: Adhere to the following for wall thimble installation: 1. Select the point of penetration where a minimum of 1/4” per foot upward pitch can be maintained. 2. When penetrating a non-combustible wall, the hole through the wall must be large enough to maintain the pitch of the vent and provide sealing.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 FIGURE 19 - HORIZONTAL INSTALLATION WALL PENETRATIONS intake and vent pipes are passed, then tighten securely. They will prevent the intake and vent pipes from being pushed or pulled. Horizontal Vent Termination Adhere to the following for horizontal vent terminations: 1. Join the vent termination to the vent pipe outside the Questions? Call (315) 298-5121, or visit us online at www.fulton.com wall. Use the same joining procedures for vent pipe and fittings.
INSTALLATION ! PHW-IOM-2013-0214 SECTION 2 WARNING Do not attempt to start the boiler before filling and purging the boiler system. A dry fire may cause injury, may seriously damage the boiler, may result in property damage, and will void the warranty. FIGURE 20 - WALL THIMBLE INSTALLATION 7 feet above finished grade, (National Fuel Gas Code, ANSI Z223.1). 3. The vent termination must be at least 4 feet (1.22m) horizontally from, and in no case above or below, unless a 4-foot (1.
SECTION 2 4 3 2 1 INSTALLATION PHW-IOM-2013-0214 HIGH POINT AIR VENT (TYPICAL) 8 Legend: 5 7 VENT 6 COLD WATER SUPPLY 11 12 13 10 9 10 BOILER 7 * RETURN FROM SPACE HEATING SYSTEM DRAIN 14 9 *ALTERNATE LOCATION 1. Temperature/ Pressure Indicator 2. Hot Water Outlet Stop Valve 3. Safety Valve 4. Combo Shutoff/ Purge Valve 5. Auto Air Vent 6. Air Scoop 7. Circulator 8. Heat User 9. Zone Valve 10. Stop Valve 11. Check Valve 12. Pressure Reducing Valve 13. Diaphragm Expansion Tank 14.
INSTALLATION 4 PHW-IOM-2013-0214 SECTION 2 system may be considered water tight. CAUTION Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water damage can occur. 10. When purging is completed, make sure the following are open— combination shut-off/purge valve, shutoff valve to pressure reducing (fill valve), shutoff valve in cold water fill line, and shutoff valve in return line. 11.
SECTION 2 INSTALLATION PHW-IOM-2013-0214 Rating the Boiler After the boiler has been operating for about 15 minutes, check gas input rate to be sure boiler is operating at design capacity. To Check for High Gas Pressure Adhere to the following: 1. The boiler and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1/2 psig (3.5 kPa). FIGURE 22 - REMOVING CAP FROM REGULATOR 2.
INSTALLATION reliability problems. Regulators, other than specified, may be acceptable, but it has been our experience that Fisher regulators operate the most satisfactorily. 4. Recommendations for installing step down regulators: § There must be a minimum of 10 pipe diameters of straight pipe before the inlet and after the outlet of the regulator. PHW-IOM-2013-0214 SECTION 2 Before Leaving the Installation 1. Check all controls to insure they are operating properly.
OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.
OPERATION ! 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. Failure to follow instructions may result in a fire or explosion, causing property damage, personal injury, or loss of life. PHW-IOM-2013-0214 SECTION 3 Before Start Up Fulton Pulse combustion boilers do not have a pilot.
SECTION 3 OPERATION PHW-IOM-2013-0214 3. Set temperature control to desired setpoint. 4. Turn operating switch on boiler to “ON” position. The boiler is energized and 35 second prepurge begins. After 35 seconds the spark ignitor and gas valve (2 seconds later) are energized. If combustion is not sensed within 4 seconds, gas and spark are de-energized. The control will recycle to prepurge, only if the allowed number of retry attempts is not exceeded. 5.
OPERATION ! WARNING Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer. 4 CAUTION After checking controls by manual adjustment, make sure they are always reset to their proper settings.
SECTION 3 OPERATION PHW-IOM-2013-0214 6. Check combustion at high fire. Make adjustments to air flapper, and incoming gas. Air flapper adjustments are to be made at high fire only. 6. Set the 4-20 mA source to 4 mA to drive the motor to the closed position. ´ NOTE: At high fire, the gas and exhaust butterfly valve will be full open in the horizontal position. 7. Turn the start potentiometer slowly counterclockwise until the motor begins to open. This is defined as the start or zero position.
OPERATION instructions to shut off the gas and call your service technician and/or gas supplier: 9. Turn off all electric power to the boiler if service is required. 10. Turn gas cock handle clockwise to “OFF”. Sequence of Operation for Modulated Pulse Hydronic Boilers The following is a typical sequence of operation: 1. When the boiler receives a call for heat, the prepurge cycle is initiated. 2. The mod motor is driven to high fire.
SECTION 3 OPERATION PHW-IOM-2013-0214 PRIMARY SCREENS ON THE SOLA CONTROL SOLA Control Screen Example Screen Shot Home Screen Touch the SOLA to access the Status Summary Screen. Status Summary Screen From this screen the control can be configured. It also provides a snap shot status of the boiler. Central Heat Operation Screen From the Status Summary Screen press the Operation button.
OPERATION SOLA Control Screen PHW-IOM-2013-0214 SECTION 3 Example Screen Shot Firing Rate Screen In this example screen, the boiler is in automatic. By pressing the circle next to Manual in Run, the unit will go to manual. Pressing Clear will remove the current firing rate percentage and permit you to enter a new percentage. Press OK. The boiler will go to that firing rate. Setpoint Screen Access this screen by pressing the yellow highlighted box next to Normal from the Central Heat Operation Screen.
SECTION 3 OPERATION PHW-IOM-2013-0214 SOLA Control Screen Example Screen Shot Central Heat Configuration – Modulation Screen By pressing the black arrow on the top of the page you will be able to move from the previous Setpoint screen to the Modulation Screen, In this screen you will have access to the PID (Proportional, Integral and Derivative) of the control. The sola password is required to change these parameters. Statistics Screen From this screen you can view cycles and hours of the boiler.
OPERATION ! 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. Non-Fulton product information is for reference purposes only. No Fulton document should substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION PHW-IOM-2013-0214 be done by pressing the reset button on the front of the Sola control (the base) for 1 to 2 seconds. See Figure 30. ! 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. Non-Fulton product information is for reference purposes only.
OPERATION 4 WARNING PHW-IOM-2013-0214 SECTION 3 information on the lockout can be displayed. This expanded annunication will assist in troubleshooting. Pressing Clear Lockout will clear the current lockout. See Figure 32. 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.
SECTION 3 OPERATION PHW-IOM-2013-0214 ! CAUTION 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
OPERATION ! PHW-IOM-2013-0214 SECTION 3 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION PHW-IOM-2013-0214 temperature. Minimum outdoor temperature relates to Central Heat Setpoint. See Figure 38. Minimum boiler water temperature should be the lowest temperature at which you want the boiler to function. 4. Master Boiler – While still in the Advanced Settings Screen, arrow over to Central Heat and Select your Setpoint. This is what your Minimum outdoor temp will relate to on the curve.
OPERATION ! WARNING PHW-IOM-2013-0214 SECTION 3 you can look at your curve in the previous screen, press Show Line. See Figure 39. Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections of this manual and are qualified to operate/maintain the equipment. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION PHW-IOM-2013-0214 7. For the Slave Boiler(s), go to the Configuration Menu, select Lead Lag Slave Configuration and select Slave Enable - Enable slave for built-in Lead Lag Master. See Figure 41. 8. Master Boiler - Sensor Selection: In the Configuration Menu go to Sensor Configuration. Press sensor Outdoor temperature source, select Enviracom Outdoor Sensor. Also change S5 (J8-11) sensor to 10K NTC single nonsafety, this is your header sensor. See Figure 42.
OPERATION ! PHW-IOM-2013-0214 SECTION 3 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION PHW-IOM-2013-0214 ! 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. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
OPERATION ! 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. PHW-IOM-2013-0214 SECTION 3 5. Back out to the Configure Screen and press Sensor Configuration. The “sola” password will need to be entered. Press the Outdoor temperature source and choose EnviraCOM outdoor source. See Figure 49.
SECTION 3 OPERATION PHW-IOM-2013-0214 Third Party SOLA Control The Pulse SOLA Control provides the capability of control and/or monitoring by a third party. The standard SOLA control protocol is Modbus. ¡ Lead/Lag Outdoor Reset Configuration Using Communication Port 2 If the boilers are set up to be lead/lag with outdoor reset all the communication connections on the J3 plug of the SOLA control will be used. Third party control can be wired to the SOLA display on communication port 2.
OPERATION Honeywell Sensor and Well Outdoor Sensor Interface Module, mounted inside as close to outdoor sensor as possible He ad er Se ns or 1 SECTION 3 PHW-IOM-2013-0214 Outside Air Sensor 2 wire, landed on “OT” of interface Module, Field Wiring Outside Wall 2 3 Wires Connected to Master Boiler (J3 ECOM terminals 1,2 and 3), Field Wiring r so en rS o tdo Ou Outdoor Sensor Interface Module 3 Field Wiring 1 2 3 OT OT 4 Clamp Filter all connections to D display 2 Honeywell Header Sensor an
SECTION 3 PHW-IOM-2013-0214 OPERATION FIGURE 52 - EXAMPLE/TYPICAL ELECTRICAL DIAGRAM Questions? Call (315) 298-5121, or visit us online at www.fulton.
OPERATION 3-24 PHW-IOM-2013-0214 SECTION 3 © The Fulton Companies 2013
MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.
MAINTENANCE ! 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. Prior to any maintenance concerning electrical components of this equipment, ensure electrical supply to the equipment is disconnected. Label all wires prior to disconnection; wiring errors may cause improper and hazardous operation.
SECTION 4 MAINTENANCE PHW-IOM-2013-0214 § Immediate repair of all leaks. § Maintenance of system pressure. 6. Check condensate trap to be sure it is clear of debris. Also ensure condensate is not backing up into the boilers. Annual Maintenance and Inspection Schedule Annual maintenance and inspection must include the following: 1. On units utilizing a flame rod, the flame rod should be changed. The flame rod is located in the top of the boiler for PHW-300-1400, and inside the injector on PHW-2000. 2.
MAINTENANCE 4 PHW-IOM-2013-0214 SECTION 4 CAUTION 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. All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Representative.
SECTION 4 MAINTENANCE PHW-IOM-2013-0214 Troubleshooting Use the following table as a guide to troubleshooting your boiler. Problem Starting or Purge Failure Cause Check Power Supply Check fuse or circuit breaker. Reset or replace, as necessary. On/Off Switch For all models check to see if on/off switch has loose wires. Bad Air Switch Try adjusting sensitivity of switch or replace. Bad Fan Check fan for operation. Replace if necessary. Flame Rod Check for carbon buildup, cracks in porcelain.
MAINTENANCE 4 CAUTION 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. PHW-IOM-2013-0214 SECTION 4 Reviewing Diagnostics on SOLA Control From the Status Summary screen press Diagnostics (see Figure 55) . All maintenance procedures should be completed by trained personnel.
SECTION 4 MAINTENANCE PHW-IOM-2013-0214 4 CAUTION 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. FIGURE 57 - I/O STATUS DETAIL ¡ Taking Screen Shots All maintenance procedures should be completed by trained personnel.
MAINTENANCE PHW-IOM-2013-0214 SECTION 4 4. Select an existing screen shot in the list and then select Copy to USB. Selecting View allows you to look at a particular screen shot before you copy it. See Figure 61.
WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.
WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5 Standard Warranty for Fulton Pulse Boilers Models PHW with Carbon Steel Exhaust Pipes Ten (10) Year (120 Month) Thermal Shock Warranty Fulton Heating Solutions guarantees the Pulse hot water pressure vessel against thermal shock for a period of ten (10) years when the boiler is installed as a closed loop hot water boiler and is operated per the Installation and Operation Manual.
SECTION 5 PHW-IOM-2013-0214 WARRANTY & PARTS Standard Warranty for Fulton Pulse Boilers Models PHW with Duplex Stainless Steel Exhaust Pipes Ten (10) Year (120 Month) Thermal Shock Warranty Fulton Heating Solutions guarantees the Pulse hot water pressure vessel against thermal shock for a period of ten (10) years when the boiler is installed as a closed loop hot water boiler and is operated per the Installation and Operation Manual.
PARTS & WARRANTY ! WARNING Use of non-factory authorized replacement parts is not recommended for this equipment. Use of non-factory authorized parts may jeopardize safety and system performance, and voids the product warranty. PHW-IOM-2013-0214 SECTION 5 Parts Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial number of your Fulton boiler ready.
SECTION 5 WARRANTY & PARTS PHW-IOM-2013-0214 ¡ PARTS PHW Part # Description 2-30-000232 Air switch-purge fan 2-30-001334 Air switch -proof of flame 2-30-000290 Blocked intake switch 2-30-000291 Blocked intake switch 2-30-001360 Blocked exhaust switch 2-12-000551 Air flapper gaskets (replaced 2-12-553) 2-12-000554 Air flapper gaskets 2-22-000181 Air flapper spacer - .030 2-22-000182 Air flapper spacer - .050 2-22-000183 Air flapper spacer - .040 2-22-000186 Air flapper spacer - .
WARRANTY & PARTS SECTION 5 PHW-IOM-2013-0214 PHW Part # Description 2-40-000253 Gas valve w/P.O.C.
SECTION 5 WARRANTY & PARTS PHW-IOM-2013-0214 PHW Part # Description 2-20-000655 Gas orifice 2” x .500 2-20-000656 Gas orifice 2” x .540 x 2-20-000656 Gas orifice 2” x .540 (post 05/2003) x 2-20-000657 Gas orifice 2” x .
WARRANTY & PARTS SECTION 5 PHW-IOM-2013-0214 PHW Part # Description 300 500 650 750 950 1000 1400 2-30-000145 Safety Valve 3/4” X 1” 100# x x x x x x x 2-30-000020 Safety Valve 3/4” X 1” 125# x x x x x x x x 2-30-000166 Safety Valve 3/4” X 1” 160# x x x x x x x x 2-30-000851 Safety Valve 1” X 1-1/4” 30# x 2-30-000951 Safety Valve 1” X 1-1/4” 60# x 2-30-000269 Safety Valve -1 1/4” X 1-1/2” 160# 2-30-000266 Safety Valve 1-1/4” X 1-1/2” 60# 2-30-000221 Safety
SECTION 5 WARRANTY & PARTS PHW-IOM-2013-0214 PHW Part # Description 2-20-000023 Low water probe 3” 2-20-000108 Water probe for exhaust decoupler-13” 2-20-000012 Water probe for exhaust decoupler - 11-1/4” 2-20-000109 Water probe for exhaust decoupler-15” 2-45-000091 300 500 650 750 950 1000 1400 2000 x x x x x x x x x x x x x x x x On/off toggle switch x x x x x x x 2-45-000339 Green 3-position switch light x x x x x x x x 2-45-000307 Green 2-position
WARRANTY & PARTS SECTION 5 PHW-IOM-2013-0214 PHW Part # Description 2-35-000532 1-1/4” x 16” gas flex connector 2-35-000801 1-1/2” x 16” gas flex connector 2-30-000836 Steam hose - 1-1/4” ID x 1-3/4” OD - con drain 2-12-001000 Insulation - 2” x 24”W x 48”L /sheet 2-30-000498 MM flow switch - #FS-4-3-P x x x x x x x x 2-45-000040 1/2” Knockout plug x x x x x x x x 4-57-000500 Air spacer kit (old style) x x 4-50-RK0420 Air flapper repair kit x x x x 8-00-002000 Spar
SECTION 5 PHW Part # WARRANTY & PARTS PHW-IOM-2013-0214 Description 300 500 650 750 950 1000 1400 2000 Standard spare parts kits include (1) air flapper gasket set, (1) gas flapper gasket set, (1) spark plug and (1) flame rod. Extended spare parts kits include (1) air flapper gasket set, (1) gas flapper gasket set, (1) spark plug, (1) flame rod, and (1) programmer control. Heat Fab venting material available - consult factory Questions? Call (315) 298-5121, or visit us online at www.fulton.
WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5 THIS PAGE INTENTIONALLY LEFT BLANK 5-12 © The Fulton Companies 2013
SECTION 5 WARRANTY & PARTS PHW-IOM-2013-0214 THIS PAGE INTENTIONALLY LEFT BLANK Questions? Call (315) 298-5121, or visit us online at www.fulton.
WARRANTY & PARTS PHW-IOM-2013-0214 SECTION 5 THIS PAGE INTENTIONALLY LEFT BLANK 5-14 © The Fulton Companies 2013
No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies. Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems. © The Fulton Companies 2013 The heat transfer innovators.