Fulton Pulse HW (PHW) Fully Condensing Hydronic Boiler - Manual (Page 3)

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