FULTON PulseHW Series Manual de usuario

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: (315) 298-5121

Facsimile: (315) 298-6390

www.fulton.com

Serial # __________________________

Model # __________________________

Fulton Order # __________________________

Sold To __________________________

Job Name __________________________

Date __________________________

Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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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)

Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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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

Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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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.

Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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Section 1

Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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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.

Fulton Heating Solutions, Inc. -- PHW Manual -- 2010-0713

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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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