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Pulse DWH IOM
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1. Re p I ace m e nt P a rts available from authorized Fulton Representatives Models PDWH 750 1000 Part Number Description Accessories 2 45 000212 H O A Switch 0 Instruction Manual 4 57 000440 Condensate drain kit x x 2 10 000168 Condensate drain float assembly 2 35 000863 Isolation cube 2 35 000865 Isolation spring grey 221 Seismic iso spring 221 2 14 flex cont water 7272 2 1 2 x 16 flex cont 221 1 gas flex cont x 2 35 000532 1 1 4 gas flex cont 2 30 000498 FS 43 MM Flow switch 0 Knockout cover x x 2 23 000170 Paint Tech Tan spray 4 oz 4 23 000016 Paint Tech Tan quart x x 2 35 000799 PVC Air intake adaptor 4 x x 5 10 002765 4 S S muffler intake 5 10 002755 4 S S muffler exhaust 2 35 000059 4 flex connector intake 4 57 000168 4 PVC term w screen coupling 4 57 000164 4 PVC term w screen 45 deg elbow 4 57 000170 4 PVC term w screen 90 deg elbow Air flapper spacers air flapper valve assemblies and gas orifices must be requested by contacting your authorized Fulton representative Please advise serial number on purchase order or quote request 40 PDWH Re p a ce m e nt P a rts available from authorized Fulton Representatives Vent Material 4 Single
2. OFF 7 NA 4 6 Turn the on off switch to ON To Check for High Gas Pressure 1 The water heater 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 2 Turn off water heater and turn off gas supply to manual gas shutoff valve Remove the pressure test plug on manual shutoff gas valve Replace with a 1 4 NPT to 1 4 compression or flange adaptor and a short piece of tubing Connect a piece of rubber hose from tubing to one side of manometer 3 Open gas supply to manual gas shutoff valve and turn on water heater After combustion starts manometer should read 7 WC 178mm minimum for natural gas and 1 WC 25mm minimum for propane 4 If reading exceeds 7 0 WC 178mm install regulator upstream of gas valve to reduce pressure Pressure for Natural gas should measure 1 to 3 WC at the last elbow the gas train at high fire or full rate on on off units For more specific information consult the test fire report which is included in the User Manual There should be 7 WC at the inlet of the train Pressure for propane should be 11 WC at inlet to the gas train To Correct Input Adjust Gas Pressure Regulator Turn water heater off and remove cap from regulator Figure 17 Turn adjusting screw clockwise to increase gas flow Turn adjusting screw counter c
3. 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 TH EL ROP PERE TRA TICA A ee ee I DI 2 _ NETO NIDO nr pena pr prc soa CIRO wile 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 u E kei A Tadini 77 PEDAL a NA ar PEREA Eo Ld DELTA dl AT E re RO dei iii LARE ed Pi AR PP gt BS Po dote Ta Sia ii dba mi 4 Installation Air Intake Supply and E
4. Loose Wire Connection Temperature Control Loose Tubing Power Supply Main Control Proof of Flame Switch Flame Rod Option Loose Wire Connection Air Flappers Gas Flappers Plugged Exhaust Line In AII Cases Air Flappers Gas Flappers Plugged Air Inlet Problem Starting or Purge Failure Flame Failure Poor Combustion Recommended Troubleshooting Check the relay module and display module connections Reset and sequence the 7800 Check the 7800 power supply to assure that both frequency and voltage meet specifications Check the backup power supply as appropriate Check the relay module and display module connections Reset and sequence the 7800 Check the 7800 power supply to assure that both frequency and voltage meet specifications 1 2 3 4 1 2 3 Maintenance Troubleshooting Fault Code Diagnosis Fault Code System Failure Fault 02 Excess noise or device running on AC Frequen Noise slow AC Fault 03 AC Line dropout detected AC Line Dropout 4 Check the backup power supply as appropriate Check the relay module and display module connections Reset and sequence the 7800 Check the 7800 power supply to assure that both frequency and voltage meet specifications Check the backup power supply as appropriate Check the relay module and display module connections Reset and sequence the 7800 Check the 7800
5. 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 Fa LI Sf ui Di im Ri gt EX LEE Contents Safety Warnings and Precautions 3 Installation 7 Operation 25 Maintenance 33 Parts and Warranty 37 1 PDWH O1PON Section 2 PDWH Section Safety Warnings and Precautions 3 PDWH For Your Safety 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 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 ope
6. Wall Stainless Steel Roof sup jack assy 5480C1 Vent termination 5490C1 4 Pulse adapter 7401FUL 3 x 4 increaser 7374GC 4 x 3 decreaser 7473 Rain cap 7400GC x 6 vent 7401GC x 12 vent 7402GC x 18 vent 7404GC x 24 vent 7405GC x 36 vent 7407GC x 48 vent 7408GC 45 elbow 7411GC 90 elbow 7414GC vent tee 7416GCD boot tee 7416GCB drain cover 7417GCD support clamp 7423GC x18 adjustable 7424GC strm spt collar 7426GC boot tee w 3 take off 7443GCB horizontal termination 7490GC 6 x 16 cover plate 7473GC Rain cap 7300GC Pulse adapter 7301FUL x 6 vent 7301GC vent 7302GC 12 x 18 vent 7304GC x 24 vent 7305GC x 36 vent 7307GC x 48 vent 7308GC 45 deg elbow 7311GC 90 deg elbow 7314GC vent tee 7316GC vent boot tee 7316GCB vent tee cover w drain 7317GCD x 18 adjustable 7324GC horizontal termination 7390GC horizontal support 7323GC Hi temp sealant 10 oz 7000RTV Sealant 5 oz 7OOORTVL Sealant 10 oz PP PP E PB G2 09 OO 9 Pr Part Number 2 35 000987 212 21 0 23 23 200 21 22 23 2 24 25 26 27 222 2020 2 35 000985 2 35 000572 2 35 000984 2 35 000961 233 2 21 21 22 23 244 25 26 27 21 2 35 000992 2 35 000993 2 35 000994 2 35 000995 2 35 000997 2 35 000998 2
7. anytime WARNING Do not use matches candles flame or other sources of ignition to check for gas leaks 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 CANADA 13 PDWH 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 Installing Gas Piping Figure 4 N
8. be horizontal in orientation NOTE The unit will still shut off at setpoint plus 5 F standard settings Also being in manual mode the temperature control ignores any PID or auto tune settings 10 Set the temperature back to the Auto setting by pressing the A M key the operating and setpoint temperatures will be displayed in the PV and SP displays respectively The longer the radius on the exhaust valve pivot arm the slower the exhaust butterfly valve shuts off Conversely the shorter the radius the quicker the exhaust butterfly valve shuts off At High Fire the linkage arms should NOT begin or finish travel in the vertical position If this occurs there is a possibility that the gears will bind and cause damage to the mod motor The gas pressure regulator is the only means for adjusting High Fire input to the factory test fire values After the water heater is operated at High Fire to the desired settings proceed to operate at Low Fire Low Fire Settings Manually adjust the temperature controller on the front of the water heater to read 50 input At 50 check to see if the unit is within test fire values Proceed to step the water heater down to 40 30 20 10 and 0 each time checking to see if the unit is within test fire values 0 represents low fire and 100 represents high fire If you are unable to reach 0 you will need to make adjustments on the gas valve to either increase or de
9. control is in Operator mode The PV Display will show oppa Repeat Parameter Setting Procedure 9 When the PID parameter appears in the PV Display press one of the Arrow keys until 1 appears in the SP Display press SET ENT this will take you to a subset of parameters Repeat Parameter Setting Procedure 10 After confirming or entering the PID value 1 MR the control automatically returns to the remaining Operating parameters Repeat Parameter Setting Procedure 11 When finished hold SET ENT key to return to Setpoint Temperature Water heater is ready for operation NOTE If the rh Range High value has been changed in the Input Output Menu the Setpoint Temperature will read zero 0 after return from the menus Simply press the Up Arrow key until the desired setpoint value is shown Hit SET ENT once to store and begin operation Operation Sequence of Operation for Modulated Pulse Water Heaters 1 When the water heater receives a call for heat the prepurge cycle is initiated 2 The mod motor is driven to high fire 3 After the high fire switch in the mod motor is closed the prepurge count begins 4 Following prepurge the spark generator energizes and the gas valves open 5 Upon proof of flame the fan and spark are turned off 6 At this point the modulation temperature controller controls the mod motor and firing rate of the water heater 7 When the water heater outlet temperature
10. 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 16 PDWH 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 17 PDWH 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 s
11. maintenance outlined in this section should be adhered to The water heater should be inspected annually All service should be per formed by a certified contractor At Start Up Check air intake and exhaust vent outlet for any blockage or restrictions Check for any leaks in exhaust piping Check for any leaks in the water piping Check the air intake and exhaust vent piping for sagging Follow purge procedure outlined in Section 2 of this manual Follow start up procedure outlined in Section 3 of this manual With the water heater running check for visible cracks at fittings and joints WARNING Keep water heater area clear and free from combustible materials gasoline and other flammable vapors and liquids Check anode and replace as necessary NOTE The anode is crucial to maximizing the life of the water heater 35 PDWH Maintenance Troubleshooting This troubleshooting guide will assist in the diagnosis and correction of minor field problems It should be used in conjunction with the unit wiring diagram In any case requiring additional assistance the Fulton Service Department should be contacted Check Check fuse or circuit breaker Reset or replace as necessary For all models check to see if on off switch is illuminated Try adjusting sensitivity of switch or replace Check fan for operation Replace if necessary Check for carbon buildup cracks in porcelin Check for bad groun
12. piece of rubber hose from tubing to a manometer Open the gas shutoff valve gas cock and turn on water heater The following pressures are for reference only Depending on the calorific value of the gas and length of intake and vent piping the actual pressure can be signifi cantly higher or lower mA AP Figure 17 NOTE It is recommended that an autho rized Fulton Pulse start up agent or your gas utility make any required gas input adjustments 25 PDWH PAGE INTENTIONALLY LEFT BLANK Section Operation 26 PDWH Starting the Fulton Pulse Water Heater NOTE Prior to starting make sure the proce dure for purging the system has been accomplished as detailed in Section 2 Open the main gas cock knob counter clockwise 1 4 turn to ON Figure 19 Turn on all electric power to the water heater Turn operating switch on water heater to ON position The water heater is energized and the 35 second prepurge begins After 35 seconds the spark ignitor and gas valves 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 selected number of retry attempts is not exceeded Flame Rod Option Spark Plug High Temp Limit Thermocouple gt ow Water z di Probe Se IAS PAIN If after 37 seconds the gas valve opens but the water he
13. power supply to assure that both frequency and voltage meet specifications Check the backup power supply as appropriate Check wiring correct any errors Inspect the fan assure that there is no blockage of the air intake and that it is supplying air Assure that the Airflow Interlock switches are functioning properly and that their contacts are free from contaminants Reset and sequence the 7800 to Prepurge Measure the voltage between terminal 7 and G ground 120 Vac should be present Inspect the jumper connections Assure that clipped jumpers have been completely removed Reset and sequence the 7800 If fault persists replace the relay module Check wiring correct any errors Inspect the Combustion Pressure Switch to assure that it is functioning properly Reset and sequence the 7865 During standby or prepurge measure the voltage between terminal 20 and G ground 120 Vac should be present If not the combustion pressure switch may be defective and need replacement If fault persists replace the relay module Check wiring correct any errors Inspect the Purge Fan Switch terminal 18 and connections Assure that the switch is functioning correctly and is not jumpered or welded Reset and sequence the 7865 If the fault persists replace the relay module Inspect the Purge Fan Switch terminal 18 and connections Assure that the switch is functioning correctly Reset and sequence the 7865 If the fault persi
14. 1 4 RV61 7 37 000201 Gas flapper valve assy x x 2 12 000552 Gas flapper gaskets x x 2 35 000687 Gas decoupler compression ell x x Gas Orifices Call local representataive for specific orifice 2 30 000201 Pres Temp Gauge 0 320 OF 0 75PSIG X 73 Pres Temp Gauge 0 3200F 0 200PSIG 75 Purge blower motor fan 1 RM7865A Programmer 72 RM7865B Programmer Flame Rod x x 2 40 000268 Amplifier for RM7865B x x 2 40 000270 Base for RM7865 2 Display Module for 7865 2 30 000285 T amp P Safety valve 3 4 x 1 150 20700 Spark plug x x 2 40 000980 Spark plug wire x x 2 40 001011 Flame Rod 0 Spark plug bushing 2 Spark generator 21 Terminal block 31 Ice cube relay 7 Base for ice cube relay 21 Low water safety relay 73 Base for LWCO relay 270 Retainer spring for LWCO relay 4 Remote off local switch light 3 position 27 On off switch light green 255 Low water reset push button light red 21 Flame failure light red 12 Call for heat light green 3 Light bulb only 2 45 000306 Flame failure light 3 Time Delay Relay Flame Rod 077 Spark Plug Boot 200 Spark Plug Connector 39 PDWH
15. 3 and 51874 German Patent Number M9104923 7 Benelux Registration Numbers 21548 01 02 03 04 and 21548 05 06 French Registration Numbers 0304011 0304015 and 0304016 Other patents pending Fulton Heating Solutions 972 Centerville Road Pulaski NY 13142 Phone 315 298 5121 Fax 315 298 6390 A global manufacturer of steam hot water and thermal fluid heat transfer products www fulton com
16. 35 000996 2 60 000114 2 Misc 2 Misc Contact Fulton for 6 venting material Any venting material must be listed by a recognized testing agency 41 PDWH PAGE INTENTIONALLY LEFT BLANK 42 PDWH Standard Warranty for Fulton Pulse Domestic Boilers Warranty Valid for Models PDWH Ten 10 Year 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 and is operated per the Installation and Operation Manual This guarantee will cover damage due to thermal shock such as leaks in the heat exchanger This guarantee does not cover damage due to corrosion scaling sooting or improper installation or operation The inlet and outlet water temperature differential across the boiler cannot exceed 100 F a Five 5 Year 60 Month Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of five 5 years from the date of shipment from the factory Fulton will repair or replace F O B factory any part of the equipment as defined above provided this equipment has been installed operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton The commissioning agency must also successfull
17. Installation Fulton Gas Fired Operation And Pulse Commercial Maintenance Water Heaters Manual December 2009 Rev C June 2011 PDWH750 PDWH1000 Model PDWH750 is no longer offered but is kept in this manual for reference purposes on previous equipment purchases Fulton Pulse Water Heaters The Modern Approach to Commercial Water 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 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
18. OTE See the above chart for required pipe size based on overall length of pipe from meter plus equivalent length of all fittings Approximate sizing may be based on 1 000 BTU for 1 cubic foot of natural gas 1 Gas Piping should be installed in accordance with National Fuel Gas Code ANSI 2223 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 Figure 4 50 amp PHYO FROM OPERATIVO TEMPERATURE QON TROL Figure 5 Installation 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 resu
19. OTE 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 amp 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 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 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 te
20. P VIEW AIR INTAKE PIPING Number of 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 EXHAUST VENT PIPING 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 9 PDWH Figure 2b u Se A lg FARBEN ifii a f A em i PIA oe ode Mil H bracket between the water heater and the housekeeping pad or structural floor Ifan 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
21. Super Function On Off Target Setpoint PID Parameter PV Input Filter PV Input Bias Rising Value Setting Descending Gradient Output High Limit Output Low Limit Hysteresis On Off Direct Reverse Action Heater Disconnect Heater Disconnect Heater Disconnect Heater Disconnect On Off Rate Detection On Off Rate Upper Limit On Off Rate Lower Limit On Off Rate Target Setpoint 1 Target Setpoint 2 Target Setpoint 2 Target Setpoint 4 SYMBOL AL1 AL2 AL3 AT SC Pld FL BS UPR DNR OH OL H DR HB1 HB2 HC1 HC2 ORB ORH ORL OR 1 SP 2 SP 3 SP 4 SP Note Parameters with bold values only will be used DEFAULT VALUE FULTON VALUE 100 5 0 0 100 0 off off off off 1 1 0 Enter 1 for PID Menu then 0 off 0 eus 0 0 0 off off off off 100 100 0 0 0 10 0 10 0 0 off off off off off off off off eus 1 0 0 100 100 0 0 0 0 0 0 0 0 0 0 0 0 PID Functions DEFAULT VALUE FULTON VALUE 5 10 240 off off off 60 0 5 5 240 240 60 60 3 3 100 100 100 100 0 5 0 5 DESCRIPTION Proportional Band Integral Derivative Manual Reset Proportional Band Integral Time Derivative Time Dead Band Reference Point 1 Reference Point 2 Reference Deviation SYMBOL RDV Note Parameters with bold values only will be used 1 Turn water heater OFF 2 Put the temperature c
22. TC 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 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 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
23. 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 Figure 26 _ 5 a E HA i 3 A ER mi la 1 g TT E al niert T 7 ea ns Me 4 5 I TERA en i the bolt is within 1 s 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
24. as go to the next step CLOSED Turn gas cock knob counterclockwise one quarter turn to ON Turn on all electric power to the water heater Set the thermostat to the desired setting 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 Set the thermostat to the lowest setting 2 Turn off all electric power to the water heater if service is to be performed Turn gas cock knob clockwise to OFF one quarter turn 6 PDWH Section Installation 7 PDWH PDWH1000 1 000 000 880 000 NG LPG 1 400 Ibs 2 150 lbs 300 lbs ft2 120 60 1 7 W C NG 11 W C LPG 4 0 160 PSI 27 5 IN 76 IN 37 8 IN 1055 Installation General specifications and information about Fulton Pulse Potable Water Heaters 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 In some cases the approval authority may insist that the installation conform to the American Society of Mechan
25. ater 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 a CERSA ER be TOP VIEW Installation 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 wat
26. ater does not start check the spark plug to be sure it is working properly The plug may be bad or the plug wire may be loose Check gap of plug It should be 050 to 060 When replacing plug be sure to use Never Seize on threads of plug When the unit fires and pressure is sensed in air valve housing the unit will continue to operate until main power 5 shut off to the controller either through the temperature switch or main power switch Once the pressure is sensed in the air valve housing proof of flame the blower and spark will turn off 1 Set the water temperature to desired setting HEAT OFF ON pemano 2 4 2 Turn off all electric power to the water heater Figure 18 3 Turn gas cock knob clockwise to OFF Figure 18 This gas cock knob is also the emer gency shut off device This water heater is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow safety information If you don t smell gas go to next step Operation Post these instructions in an appropriate place near the water heater and maintain in good legible condition WARNING If you do not follow these instruc tions exactly a fire or explosion may result causing property dam age personal injury or loss of life Fulton Pulse water heaters do not have a pilot They are equi
27. be maintained wall thimble must be used See next page Figure 14 for installation instructions Figure 13 Typical Combustible Wall Penetration Detail En TE l b pa a am Ae TAGE e ISO ALT PSP WALL Eun CLARA Ri i weis AIR TARE ARD AGT BRAND BE BEPERATED AB FAR M q topi ea lo di ano ec 0 20 PDWH TAM Weta END YEW a a AO Fe Da 0 m E fog MAA 4 if lex 1j BE 7 H pn E Aa i nl ene gt ni STATO Y METER a 0 es ee WITH eed CLAMECTISR WALL THODE SF ler After Installation Prior to Start Up 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 1 Completely fill and purge the heating system using the following sample procedure NOTE The following purge procedure is applicable to the piping configuration as shown in Figure 15 on the following page a Close combination shutoff purge valve in supply all drain cocks the shutoff valve for the pressure reducing fill valve and all manual air vents b Open all other system shutoff valves and open a faucet or other water discharge source c Water will now begin to fill the system Continue filling until a constant stream of water no bubbling is discharge
28. caused by a low line voltage The INITIATE sequence will be initiated if the operating control input is de energized during PREPURGE STANDBY The RM7865 is ready to start an operating sequence when the operating control input determines a call for heat The burner switch limits operating control inter locks critical loads and all microcomputer monitored circuits must be in the correct state for the RM7865 to continue into the PREPURGE sequence NORMAL START UP PREPURGE The RM7865 provides a PREPURGE timing of 35 seconds with power applied and the RM7865 operating control indicating a call for heat a Combustion pressure switch purge fan switch ILK burner switch limits operating control and all microcomputer monitored circuits must be in the correct operating state b The fan motor output terminal 5 is powered to start tte PREPURGE sequence c The purge fan switch ILK input must close within three seconds to start the 35 second PRE PURGE otherwise lockout occurs 28 PDWH Check for possible restrictions foreign objects snow rags leaves etc in either the air supply inlet or the exhaust outlet on the outside of the building Check reset switch Check for proper water level in the water heater low water cutoff If the water heater still does not operate follow these instructions to shut off the gas and call your service technician Turn off all electric power to the water heater if service is
29. causing the control to open the circuit Schedule 40 PVC Pipe Air Intake Water Heater Connection Pipe to Tubing Adapter 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 tum 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 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 cu
30. crease fuel input The exhaust butterfly valve may also need adjustment Start by adjusting one valve at a time The gas butterfly valve should be used to adjust Low Fire input The exhaust butterfly valve should be adjusted to set proper combustion Closing the exhaust butterfly valve will also decrease input slightly At Low Fire the linkage arms should NOT begin or finish travel in the vertical position If this occurs there is a possibility that the gears will bind and cause damage to the mod motor Procedure to Zero and Span the Modulation Motor The following procedure is done on each modulation mod motor at the factory It may be necessary to do in the field in the event the mod motor requires replacement or the mod motor linkage is moving up or down the range when there is no change in the operating or setpoint temperature difference Operation Linkage Adjustment for Pulse Modulated Water Heaters This instruction covers the adjustment of the linkage arms and rods between the modulation mod motor and gas butterfly valve and also between the mod motor and exhaust butterfly valve Prior to Start Up With the water heater off both the gas and exhaust butterfly valves will be in the closed position Setting High Fire When the water heater is energized the mod motor will be driven to High Fire driving the gas and exhaust butterfly valves to the open position At High Fire the slot in the shaft
31. d d When all air has escaped and only water is discharged close faucet or water discharge source e At this point the system has been initially filled However air pockets may still remain at high points in the system Itis possible depending on the particular system that faucet used for filling still contains nothing but air If manual vents are installed on the system high points these should be opened 21 PDWH DIL OF BOLT EACH i PLAS 3 ae Widi ai REQUIRED COLLAR AHO EFI TEIE fe ra Res Horizontal Vent Termination The vent termination is joined to the vent pipe outside the wall Use the same join ing procedures for vent pipe and fittings The termination of the vent system must be at least 12 above the finished grade or at least 12 above normal snow accu mulation level for applicable geographi cal areas Refer back to previous page Figure 13 The termination of the vent system shall not be located in traffic areas such as walk ways adjacent buildings openable windows and building openings unless the venting system is at least 7 feet above finished grade National Fuel Gas Code ANSI 2223 1 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 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment The air supply inlet and
32. d or bad control Replace control Check for blockage of air inlet line and remove Check for carbon build up moisture cracks in porcelain Check for proper gap 050 to 060 for Champion sparkplug Clean or replace as necessary Check connections to all components Check that the operating temperature control is set higher than temperature of the water heater water Check to see if the copper tubing on the air valve housing is securely connected Check fuse or circuit breaker Reset or replace as necessary Check for bad ground or bad control Replace if necessary Check adjustment of pressure switch No 2 It should be set at 1 5 W C Replace if necessary Check for carbon buildup cracks in porcelin Check connections to all components Check to see if the flappers on the air valve plate are placed correctly covering the holes Check to see if the flappers on the gas valve plate are placed correctly covering the holes Check for a blockage of the exhaust piping and remove Reset main control in panel box on flame failure Check to see if the flappers on the air valve plate are placed correctly covering the holes Check to see if the flappers on the gas valve plate are placed correctly covering the holes Check for blockage of air inlet line and remove 36 PDWH Cause Power Supply On Off Switch Bad Air Switch Bad Fan Flame Rod Option Main Control Plugged Air Inlet Spark Plug
33. e and outside of the wall through which intake and vent pipes are passed when tightened securely They will prevent the intake and vent pipes from being pushed or pulled Ensure wall thimble for 6 exhaust vent contains internal insulation prior to installation refill purge the system If no pressure drop is detected fora period of two hours under pressure the system may be considered water tight g When purging is completed make sure the following are open shutoff valve in cold water fill line and shutoff valve in return line h Make sure the following are closed all drain cocks and all manual vents 2 Open gas shutoff valve allowing gas to flow to water heater Installation to vent these locations When only water is discharged from all vents the initial purging 5 complete WARNING Never leave an opened manual air vent unattended In the event an opened vent is left unattended water damage could occur f Visually inspect all pipe joints and equipment connections for leaks If necessary drain system repair leaks and Figure 15 Piping Configuration for System Purge represents any heating load Piping Configuration for System Purge represents any heating load HOT WATER SUPPLY TO FAUCET COLD BED ena lo WATER SUPPLY 4 Glossary i Temperature Pressure Indicator Hot Water Outlet Stop Valve Safety Valve Combination Shutoff Purge Valve S
34. er 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 175 F max Capacity 4 QT Inlet Size T Outlet Size 1 1 2 Water Supply 1 4 COMP Max units to attach to drain 8 Figure 3b A g y E yoo A L E FOR MULTIPLE HEATER NETALLATICH MARTAN AA PIPE SE OF 1 FOR THE HEADER PIP HA HEATERS WARUM PER DAR HIT 12 PDWH Installation Pipe Capacity For Natural Gas Nominal Equivalent Maximum Capacity in Cubic Feet of Natural Gas Per Hour Iron Pipe Internal Pipe Length Pressure Drop of 0 5 W C Size Diameter 90b Elbow Tee Equivalent Length of Pipe in Feet 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 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
35. er 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 ko BERT 7 Ena ie 1 7 LA A i e o Pai i roger a Keen cl ik 5 co R Pr E Pr Fr E grani 2 sx 3 m re el ARSCH ee age a 1 ae 2 E i e SEE ae ij Rana tirare ij de To Lit i sei 6 15 um 1 i Fees a Es i EP i L 5 A _ T H AT Po ef a al a a ni E H q pa toe ttt ay Dial de ar RB JR s EF AEA THF 11 PDWH 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 Eac
36. erminal 6 opens indicating that the demand is satisfied or that the limit has opened If the Combustion Pressure Switch Interlock opens RM7865A or the flame signal is lost RM7865B the RM7865 will enter the POSTPURGE period The fan motor is de energized during RUN POSTPURGE The RM7865 provides a 35 second POSTPURGE following the completion of the RUN period and the fan motor output is powered to drive all products of combustion and any unburned fuel from the combustion chamber The RM7865 will also enter POSTPURGE if the operating control input is de ener gized during CPEP CPSP or RUN 1 The main fuel valve and ignition terminals 8 and 10 are de energized The purge fan switch is energized and the POSTPURGE period begins 2 After the 35 second POSTPURGE period is completed the RM7865 returns to STANDBY Operation IGNITION TRIALS Without Flame Rod Option a Combustion Pressure Establishing Period CPEP 1 The ignition transformer terminal 10 is energized two seconds prior to opening of the main fuel valve 2 The main fuel valve terminal 8 is energized for four seconds Com bustion pressure must be proven by the end of the six seconds of CPEP to allow the sequence to continue to the Combustion Pressure Stabilization Period CPSP If combustion pressure is not proven by the end of CPEP the RM7865 will recycle to PREPURGE b Combustion Pressure Stabilization Period CPSP 1 If the combustion
37. exhaust outlet must be separated from 3ft minimum to 10ft maximum on the same wall The exhaust outlet must be installed 2ft minimum above and downwind from air supply inlet to prevent exhaust recirculation Under certain wind conditions some building materials may be affected by flue products expelled in close proximity to unprotected surfaces Sealing or shielding of the exposed surfaces with a corrosion resistant material such as aluminum sheet may be required to prevent staining or deterioration Do not locate the vent termination too close to shrubbery as flue products may stunt or kill them Installation Figure 14 Nominal Pipe amp Thimble Diameters Co 35 16 43 16 61 8 Co 8 41 10 63 15 56 Pipe Size in Ag Bo 3 67 8 57 16 4 93 8 81 2 6 818 Fixed Pipe Size cm Ag Bo 7 62 17 46 13 81 10 16 23 81 9 15 24 20 64 Fixed Wall Thimble Installation A 9 diameter thimble is inserted through the wall from the outside Secure the outside flange to the wall with nails or screws and seal with adhesive material Install the inside flange to the inside wall secure with nails or screws and seal with adhesive material Pass the vent pipe through the thimble from the outside and join to the rest of the vent system Seal the pipe to the thimble flange with adhesive material Figure 14 Install two pipe retain ing clamps around the intake as well as vent pipes on both ends of the wall thimble on the insid
38. g Water Heaters DESCRIPTION Input Type Input Unit Selection Range High Range Low Scale Decimal Point Scale High Scale Low On Off Burnout Selection Output type Retransmission Retransmission High Retransmission Low Digital Input Custom Select Custom Select Custom Select Custom Select Key Lock Password SYMBOL LOCK PWD Note Parameters with bold values only will be used Functional Parameters DEFAULT VALUE FULTON VALUE 1 4 2 off 3 off 0 5 10 0 5 off 0 5 off 30 1 30 same 0 0 0 0 0 0 off off auto auto 0 1 0 0 4 4 1 1 1 1 8 8 1 1 0 0 0 0 DESCRIPTION Alarm 1 Type Alarm 2 Type Alarm 3 Type Alarm 1 Hysteresis Alarm 2 Hysteresis Alarm 3 Hysteresis Control Output Type Control Output Type Preset Output Preset Output Cooling PID Control Zone PID Control Anti Reset Windup Time Unit for Ramp Protocol Selection Communication Speed Parity Stop Bit Data Length Address Minimum Response Time Test Control SYMBOL AL1 AL2 AL3 HY1 HY2 HY3 CT CTc PO Poc C MD ZON AR TMU P SL BPS PRI STP DLN ADR RP T TEST Note Parameters with bold values only will be used 31 PDWH CUSTOMER VALUE CUSTOMER VALUE 32 PDWH Operating Parameters Operation DESCRIPTION Alarm 1 Setting Alarm 2 Setting Alarm 3 Setting Auto Tune
39. g 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 4 PDWH 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
40. h 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 pal a T LI he E AA vr E 5 5 a CE Lop E ti LOR Oe qu E are DFA RI 1 E Hi r y Ye Installation 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
41. ical 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 Models PDWH750 BTU HR Input 750 000 BTU HR Output 660 000 Fuel NG LPG Approx Dry Weight 1 800 Ibs Approx Operating Weight 2 150 lbs Floor Loading 300 Ibs ft2 Power Required 120 60 1 Min Required 7 W C NG Gas Pressure 11 W C LPG Max Amp Draw F L A 4 0 MAWP 160 PSI Water heater Width 27 5 IN Water heater Height 76 IN Water heater Depth 37 8 IN GPH 100 F Temperature Rise 790 Note Based on 40 F in 140 F out Introduction The Fulton Pulse water heater is an automatic gas fired direct vent water heater This water heater utilize
42. inless steel 300 or 400 series galvanized steel or copper piping for potable water systems incorporating a PDWH Local code requirements may also dictate feasible materials Water Quality Failure to maintain appropriate water chemistry and quality will void the factory warranty on the heater Water must be treated if it is not in compliance with the guidelines below Hardness 5 25 grains per gallon Total Dissolved Solids lt 350ppm PH Shall not be aggressive and corrosive Chlorides lt 250 ppm Pulse PDWH 1000 CGA Rating The Water heater After the water heater has been operating for about 15 minutes check gas input rate to be sure water heater is operating at design capacity Testing Ignition Safety Shut Off Open gas shut off valve allowing gas to flow to water heater Close gas shut off valve Reset low gas pressure switch Turn on the water heater The water heater will run through its purge and trial for ignition cycle After 6 seconds of ignition trial the water heater will recycle Switch the water heater off Open the gas shut off valve Restart the water heater Measure Gas Flow Rate Tum off the water heater and the manual gas shutoff valve Remove manifold down stream pressure test plug from the 90 degree elbow 24 PDWH 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 a
43. 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 Figure 2a Im 3 ui 2 ELAFTEHER CORTES a FR a lA FA SUPE WITH EN FE i Installation 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 sha
44. ll 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 10 PDWH 6 Install expansion tank 7 Clearence from hot wat
45. lockwise to decrease gas flow Always replace cap before turning on water heater Vent must terminate outdoors A flow restricting bleed valve shall not be used For High Gas Pressure Installations In high gas pressure areas it is good practice to step the pressure down as described below 1 Locate the stepdown regulator as far away from the pulse water heater as possible 2 When stepping down from more than 2 psig to 7 WC the stepdown should be done in two steps a Reduce the pressure to 2 psig b Reduce the pressure from 2 psig to 7 WC 3 The preferred regulator for this application is the Fisher S Series with lock up capability 4 Consult your Authorized Fulton Representative for selection This recommendation is made to avoid the regulators chattering It is also recommended to avoid high lockup pressures which can cause light off reliability problems Regulators other than specified may be acceptable but it has been our experience that the above listed regulators operate the most satisfactorily Before Leaving The Installation Make sure installation complies with all applicable codes Check all controls to insure they are operating properly Cycle water heater several times by raising and lowering operating temperature on the thermostat Installation Figure 16 Figure 16 Replace the plug with a 1 4 N P T to 1 4 compression or flare adaptor and a short piece of tubing Connect one
46. lt 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 Electrical Schematic NOTE Consult factory for custom control applications Figure 5a JHH Uber TUES 14 PDWH VICE BY OTHER mmmn SET m AS mi u La DEATH AHD BER a LGP Hoe LoL 120 VEURKER CROUT FUSE m E 4 a EEE m TERMINAL ELLE toni 4 PEE pE pip pnn pipip PH ju jr pre E DE IDE be lo Ep je ASMAA Annan es Glossary 6 120V power is input to the automatic AC Audible Alarm Control control relay RM7865A Optional ACR Automatic Control Rela 7 Purge blower is energized for 35 7800 series x seconds IA BM Purge Fan Motor 8 Purge fan switch is made signaling BS Burner Switch the control to proceed CR Control Relay 9 Spark plug is energized HLTC Hi Limit Temp Control 10 Gas valve is energized LW Panel Light Low Water 11 Pressure sensing switch is made Indicator proof of flame allowing sequence LWCP Low Water Cutoff Probe to continue LWRS Low Water Reset Switch 12 Pulse combustion will continue LWSR Low Water Safety Relay GV Main Gas Valve O
47. mperature 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 sprin
48. n of the valves is smooth 5 Remove the low water cut off probe and clean Replace the probe in the water heater NOTE If for any reason the air intake or exhaust vent piping is disassembled reassemble the piping in accordance with the installation procedure outlined in the installation section of this manual NOTE Should you suspect that the water heaters flue passage ways have become blocked contact your recognized Fulton representative Recommended Monthly Maintenance Inspect the air intake and exhaust vent pipes for broken seals at the joints Inspect the screens on the air intake and exhaust vent terminal and make sure they are free of dirt or any foreign matter which may block the terminals Check air intake and exhaust vent outlet for any blockage or restrictions Check for any leaks in exhaust piping Drain water heater completely and flush to remove any sediment in the tank IMPORTANT Check and record the number of operating cycles In a properly designed system a heater with modulation should not cycle more than 2 000 times per month If your water heater is cycling more than 2 000 times per month please contact your local service representative Excessive cycling will reduce the life of ANY water heater Maintenance NOTE Your Fulton Pulse 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
49. n this procedure is successfully completed 7 Repeat Step 1 and change the HY1 value back to 10 standard 8 Scroll under Operating Parameters to SC Super Function and adjust the value to on This parameter works with Auto Tune in calculating the target setpoint 9 Return to Auto mode 30 PDWH adjusted according to system design Once the desired value is displayed press the SET ENT key to maintain it in the control s memory Only those values that are Shaded with Bold amp Italic values in the menu pertain to the program constructed for Fulton pulse water heaters NOTE It is important to know that if the following parameters are altered the entire set of factory values will be altered In or UNIT located in the Input Output Menu AL1 in the Functional Parameters Menu A1 in the Operating Parameters Menu 6 After the Input Output values have been confirmed or entered return to Function mode by holding the SET ENT key until the PV display shows func Repeat Parameter Setting Procedure The HY1 parameter or Hysteresis may be adjusted to overshoot the setpoint temperature by half the value of A1 entered The unit will also start again only after the supply tempera ture decreases half the value entered below setpoint 7 After the Function values have been confirmed or entered hold the SET ENT key until the Setpoint Temperature appears in the PV Display 8 Repeat the last step until the
50. nd 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 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 Installation Installation Checkpoints HEAT LOW WATER OFF ON pemano RESET VA 4 1 Before Starting The Water Heater Do not turn on the water heater unless it is filled with water as shown by indicating light on panel box 2 Check that the front door of the air decoupler box is closed Door must be closed before starting the water heater DO NOT OPEN DURING OPERATION 3 Adjust temperature to proper set point 5 Close the circuit breaker or the fuse disconnect HEAT ON Dpemano
51. of the mod motor should be horizontal in orientation At this point it is important to note that the mod motor and gas butterfly valve linkage arms are as close to parallel as possible Also note that the mod motor and exhaust butterfly valve linkage arms should be parallel Location of the lock nuts on the linkage rods is not important Linkage Relationships The location of the linkage rods and the speed at which the butterfly gas valve and butterfly exhaust valve opens or closes will determine whether the unit operates smoothly or not Gas Butterfly Valve Side The longer the radius on the mod motor pivot arm the quicker the gas butterfly valve shuts off Conversely the shorter the radius the slower the gas butterfly valve shuts off The longer the radius on the gas valve pivot arm the slower the gas butterfly valve shuts off Conversely the shorter the radius the quicker the gas butterfly valve shuts off Exhaust Butterfly Valve Side The longer the radius on the mod motor pivot arm the quicker the exhaust butterfly valve shuts off Conversely the shorter the radius the slower the exhaust butterfly valve shuts off 33 PDWH Section Maintenance 34 PDWH Recommended Annual Maintenance 1 Change the spark plug 2 Clean replace flapper valves 3 Verify proper combustion and adjust as necessary 4 Lubricate the modulation motor arms gas and exhaust butterfly valves Ensure the motio
52. ontrol in manual mode press the A M key once the SP display will show a value between 0 and 100 3 Follow the electrical drawing and remove the connection between F and on the mod motor Disconnect relay CR3 for safety 4 Contact point 16 on the temperature control is wired through CR1 normally closed to contact point on the mod motor Contact point 17 on the temperature control must be disconnected Install a jumper from 17 to contact point on the mod motor This will provide a direct connection between and on the temperature control to and on the mod motor 5 Refer to the zero and span adjustment information for the mod motor Pages 5 and 10 Follow steps 1 through 8 on page 10 of the mod motor brochure included in the Pulse Operation and Maintenance manual 6 Be sure the linkage does not bend or catch in any position during travel 7 When zero and span are complete scroll the input rate to 100 this will drive the burner to high fire and purge any left over combustibles and adjust the blue cam if necessary until the high edge of the cam pushes against the end switch 8 Remove the jumper and install the wire on contact point 17 of the temperature control Connect relay CR3 9 Test the mod motor signal by manually setting the output signal from zero low fire 4 mA to 100 high fire 20 mA At high fire the slot in the shaft of the mod motor should
53. 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 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 Sec
54. pped with an ignition device which automati cally lights the water heater Do not try to light the water heater by hand BEFORE OPERATING Smell all around the water heater area for gas Be sure to smell next to the floor as some gas is heavier than air and will settle IF YOU SMELL GAS Do not light any appliance Do not touch any electric switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone and then follow your gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to turn the gas cock knob Never use tools If the knob will not 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 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 has been under water Before operating your Fulton Pulse Water Heater STOP Make sure you have read and followed all previous safety information 27 PDWH Causes for hold conditions in the INITIATE sequence are AC line dropout is detected AC line frequency error caused by using a 60 Hz device on a 50 Hz line or vice versa AC line noise that can prevent a sufficient reading of the line voltage inputs Brownouts
55. pressure switch is energized at the end of CPEP the RM7865 enters an eight second Combustion Pressure Stabilization Period If the combustion pressure switch ILK opens the RM7865 will recycle to PREPURGE only if the selected number of retry attempts is not exceeded After the eight seconds the RM7865 will enter the RUN period Ignition Trials RM7865B with Flame Rod Option Natural Gas Only a Main Flame Establishing period MFEP 1 The ignition transformer terminal 10 is energized for two seconds prior to opening of the main fuel valve 2 The Main Fuel valve terminal B is energized for four seconds Flame signal must be proven and the Purge Fan switch must be proven Off open by the end of the six seconds of MFEP to allow the sequence to continue to the main Flame Stabilization Period If the flame signal is not proven or the Purge Fan switch is on the RM7865 will recycle to PREPURGE if the selected number of retry attempts is not exceeded If the retry attempts exceed the limit lockout occurs b Main Flame Stabilization Period MFSP The RM7865 enters an eight second Main Frame Stabilization Period If the Flame signal is lost or the Purge Fan switch closes during this time the RM7865 will recycle to PREPURGE if the selected number of entry attempts is not exceeded If the retry attempts exceed the limit lockout occurs 29 PDWH Worksheets Use the worksheets to record the values set a
56. ration or maintenance of the equipment 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 N
57. reaches set point the water heater is tumed off and prepurge begins 8 The water heater control then monitors the outlet temperature and waits for the next call for heat NOTE A series of relays are used in the above sequence of operation Please refer to the wiring diagram for details Programming Instructions for Yokogawa UT320 Standard Program 1 Hold SET ENT key until control is in Operator mode PV display will show oppa 2 Press Down Arrow key until control is in Set Up mode PV display will show stup 3 Press SET ENT key twice until control is in Function mode PV display will show func 4 Press Down Arrow key until control is in Input Output mode PV display will show l o 5 Press SET ENT key to bring you to the first parameter in the Input Output mode Parameter Setting Procedure The values for each parameter that are shown in the PV display should match the values entered at the factory If they differ press the Up Arrow key or Down Arrow key until the factory value is displayed Some values such as High Temperature Range rh can be CUSTOMER VALUE CUSTOMER VALUE Input Output Menu DEFAULT VALUE FULTON VALUE 1 4 Cc F variable 210 variable 0 1 1 100 0 0 0 on on 1 1 0 2 1 1 variable 210 variable 0 off off off off off off off off off off off off 0 0 Operation Worksheets for Yokogawa UT320 UT350 Temperature Control Program for Pulse Modulatin
58. required Turn gas cock knob clockwise to OFF a quarter of a turn Figure 18 Page 26 Emergency Shut Down 1 Shut off electric power to the water heater 2 Shut off the main gas valve Sequence of Operation INITIATE The RM7865 enters the five second INITIATE sequence when the Relay Module is powered The RM7865 can also enter the INITIATE sequence if the Relay Module verifies voltage fluctuations of 10 15 or frequency fluctuations of 10 during any part of the operating sequence The INITIATE sequence lasts for five seconds unless the voltage or frequency tolerances are not met When the tolerances are not met a hold condition will be initiated and will be displayed on the optional display module for at least five seconds When the tolerances are met the INITIATE sequence will restart If the condition is not corrected and the hold condition exists for four minutes the RM7865 will lockout Operation DO NOT CHANGE THE PRESSURE SWITCH SETTINGS 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 If The Water Heater Does Not Start Check that the temperature control is set higher than water temperature in the water heater Check for tripped circuit breaker or blown fuse Run After the CPSP MFSP the RM7865 will enter into the RUN sequence The RM7865 will remain in RUN until the controller input t
59. rmination The vent pipe must extend through the flashing to a height above the roof as required in Figure 12 A storm collar is installed on the vent pipe over the opening between pipe and flashing Adhesive material is used over the joint between the vent pipe and the storm collar Figure 12 The vent termination is joined to the end of the vent pipe Figure 12 EGR ROCF PITCH DE FLAT TO TH Ti LG i Sean OPE HE 2 Ton F Pa 7 r 7 A a f POR SEAL E EE fa 2 SHE zz a leer ADE 3 fa AGE FITCH RSE OVER FLN RAT TO 72 15 BRACE TO ROOF AT Installation Figure 9 Fire Stopping Required For All Ceiling Floor Penetrations a Gad elit i through the four holes in the ring The fire stop is placed on top of a framed opening 141 4 square with the dished position down Nail the flange to the top of the framing For pitched roofs refer to figure 12 Cone Te ida ata 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 10 Air intake supply and exhaust vent pipes and fittings mu
60. s 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 8 PDWH Installation Figure 1 eee e chi i EH pa ce 2 e ie qui E Clearence from top dn Ks Lf of water heater to i En LA combustables must f be no less than 12 L TOR ESTA AR MET TO
61. st be securely supported For pitched roofs refer to figure 12 Horizontal sections require supports every 5 feet and at elbows From the water heater all horizontal sections must rise at least 1 4 per foot and there must be no sags or dips where condensate could collect The upward pitch is required so condensate will run back to the water heater for collection and disposal For vertical through the roof installations all gas vents extending above the roof by more than 2 1 2 feet must be securely guyed or braced inside and outside wall 2 clamps Use a support ring to attach guys or braces to the vent pipe Vertical Vent Flashing and Installation The roof opening should be located and sized such that the vent is vertical and has the required air space clearance The roof flashing is positioned with the lower portion of the base flange over roofing material Figure 11 Installation Horizontal Installation When penetrating a non combustible Minimum wall thickness through which wall the hole through the wall must be vent system may be installed is 31 4 Wall Penetrations large enough to maintain the pitch of the Maximum wall thickness through which vent and provide sealing vent system may be installed is 20 inches Figure 13 Use adhesive material to seal around the Select the point of penetration where a vent on both sides of the wall minimum of 1 4 per foot upward pitch can When penetrating a combustible wall a
62. stallations on Non Combustible Floors Only Fulton Gas Fired Pulse Water Heater Type of Gas C Natural C Propane Water Heater Model No Water Heater National Board No Year Min BTU Input Hr Min BTU Output Hr Max BTU Input Hr Max BTU Output Hr Design Pressure PSI Pounds Hr Mimimum Relief Valve Capacity Inches W C Manifold Gas Pressure Maximum Gas Supply Pressure 14 Inches W C Minimum Permissible Gas Supply Pressure for Purpose of Input Adjustment C7 Inches W C O tt Inches W C Electrical Ratings 120 Volts 60 Hz Less than 12 Amps ANS Z21 13b 1994 Low Press Boiler CAN1 3 1 1977 Industrial amp Commercial Gas Fired Packaged Boilers Minimum Wall Thickness Through Which Vent System May Be Installed 3 4 Inches Maximum Wall Thickness Through Which Vent System May be Installed 20 Inches Min Clearance to Combustibles 1 Inch Sides 24 Inches Front amp Rear by The Fulton Boller Companies a Pulaski Mew York 13142 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 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 BEFORE OPERATING smell all around the water heater area for gas Be sure to smell ne
63. sts replace the relay module Replace 7865 controller 1 2 3 Fault 4 Device running fast AC AC Frequency Fault 05 Low AC line detected Low Line Voltage Fault 32 Combustion airflow interlock fault Airflow Switch Fault 47 The configuration jumpers differ Jumpers Changed from the sample taken at startup Fault 54 Combustion pressure switch fault Comb Pressure Fault 55 Purge fan switch is on when it Purge Fan Sw On should be off Fault 57 Purge fan switch is off when it Purge Fan Sw Off should be on Faults 105 127 Call Service 37 PDWH Section Parts and Warranty 38 PDWH PAGE INTENTIONALLY LEFT BLANK Re p a ce m e nt P a rts available from authorized Fulton Representatives Models PDWH PartNumber Description 750 1000 2 30 000232 Air switch purge fan 2224 Air switch proof of flame x x 2 12 000551 Air flapper gaskets x x Air Flapper Spacers and Valve Assemblies 7 37 000124 Air flapper valve assy w o housing 1 3 Air flapper valve assy w o housing 21 Aquastat operating temp x x 2 40 000250 Aquastat high limit m r 70 Gas valve actuator w P O C IRI x x 2 40 000214 Gas valve actuator CSD 1 x x 2 30 000310 Gas valve 1 body 271 Gas valve 1 1 4 body 2 30 000306 Gas solenoid valve 1 277 Gas solenoid valve 1 1 4 2 30 000750 Gas pressure regulator 1 RV61 275 Gas pressure regulator 1
64. t PVC pipe to desired length 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 Installation 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 Figure 6 Air supply is on the top See Figure 6 For Models PDWH750 amp 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
65. t site under Customer Value If the unit is not operating correctly call your Fulton representative Have your customer values handy for trouble shooting Advanced Programming Features The Yokogawa UT320 is a sophisticated temperature control with smart features that internally calculates how close the appliance is to setpoint and adjusts it proportionally to arrive without overshooting The smart logic must be initiated in the Operating parameters by setting the following values 1 Under the Functional Parameters menu scroll to HY1 and set the value to 20 2 When the process temperature is within 10 F of the setpoint temperature scroll to AT in the Operating Parameters menu and set the value to 1 3 AT or Auto Tune will increase the modulation mod motor output to 100 until the process temperature is 2 of input span above setpoint The output will go to 0 until the process temperature decreases to 2 of input span below setpoint 4 The control will increase the mod motor again to 100 until the process temperature is 2 of input span above setpoint During this time the manual mode light on the temperature control will be flashing until completed 5 If the three samples are not the same an error message will be displayed and the temperature will drop out of Auto Tune mode Reset the zero and span adjustments on the mod motor and or adjust modulation linkage accordingly 6 PID values will be set whe
66. 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 2223 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
67. tion 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 man
68. top Valve Check Valve Diaphragm Expansion Tan Drain Valve gt 5 WATER HEATER IT Ten 22 PDWH If excessive cycling is expected to occur greater than 1 000 cycles per month a storage tank system or other custom engineered solution is required Fulton is not responsible for system designs that cause the unit to excessively cycle or have any parameters that are outside the warranty Fulto Domestic Hot Water Out To System I Storage Tank Softener If required 23 PDWH Domestic Water Cold Water Supply System Requirements Each PDWH 1000 must be configured so the temperature differential across the unit should be no greater than 100 degrees F We recommend to those personnel designing systems with a PDWH incorporate a factor of safety to ensure that the temperature differential will not be greater than 100 degrees F at any operating condition Failure to remain within this 100 degree temperature differential will void the factory warranty on the water heater Example Piping Systems Typical layout Single heater piped with storage tank This is recommended for installations where the user capacity is greater than the output of the heater or where incoming water from the city or where the difference between inlet and outlet temperature is above 100 degrees F City Well Installation Installation Guidelines Pipe Material Fulton recommends sta
69. ual air vent unattended In the event an opened vent is left unattended water damage could occur Section 2 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 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 This Water Heater is a Direct Vent Water Heater for In
70. 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 Figure 3a HE MATER EHLERS BATTERY Pros PEDO LLESH FEITE D ALL COMPROMETO ETA APR TF EN DA IO LHA 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 Figure 3c MAINTAINA PPE Ex IMPORTANT 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 he
71. writing by the Fulton Quality Manager This warranty is exclusive and in lieu of all other warranties expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose Fulton shall in no event be liable for any consequential or incidental damages arising in any way including but not limited to any loss of profits or business even if the Fulton Companies has been advised of the possibility of such damages Fulton s liability shall never exceed the amount paid for the original equipment found to be defective Excessive cycling will reduce the life of ANY boiler Verify that your system is properly designed and check cycling rate according to maintenance procedures listed in this manual To activate the warranty for this product the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval b 6 17 2011 43 PDWH PAGE INTENTIONALLY LEFT BLANK PAGE INTENTIONALLY LEFT BLANK PDWH IOM 2009 1221 Rev B 2011 0107 No part of this Installation Operation and Maintenance manual may be reproduced in any form or by any means without permission in writing from Fulton Heating Solutions Inc For more of the following patents apply to this unit U S Patent Numbers 4856558 4884963 4926789 4951706 and 5 145 345 Swiss Registration Numbers 119122 and 119243 SwdeishRegistration Numbers 5187
72. xhaust 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 Figure 8 e ral al Pla De il 2 FI re Perel Typical Ceiling and Roof Penetration Detail 18 PDWH Figure 1 Elements For Correct Roof Flashing Installation Termination height for the vent pipe must be such that no discharge opening is less than 2 feet horizontally from the roof surface and the lowest discharge opening shall be no lower than the minimum height specified in Fig 12 These minimum heights may be used provided the vent is not less than 8 feet from any vertical wall FOR ROCF FITCH OF 7232 OR MORE no Ferma TSH 61 i STRESHET a wu IAE FORGET A 7 A ORE AGIRE AWF HEH Peach 19 PDWH Figure 10 Fire Stop HEL THAAJGH 08 IH PAR PLACES 1 E f seni PLES ABRA Nail through the upper portion and sides of the base flange Use nail with neoprene washers or cover the nail heads with a neoprene plastic Finish roofing around that flashing covering the sides and upper flange with roofing material Vertical Vent Te
73. xt 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 from a neighbor s phone Follow the gas sup plier s instructions If you cannot reach your gas supplier call the fire department 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 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 STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electric power to water heater This water heater is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn gas cock knob clockwise to OFF one quarter turn 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 g
74. y complete and return the equipment Installation and Operation Checklists to Fulton s Quality Assurance department This warranty covers any failure caused defective material or workmanship however waterside corrosion or scaling is not covered Therefore it is imperative that the boiler be installed as outlined in the Installation and Operation Manual FE PETERT Five 5 Year 60 Month Prorated Flue Gas Condensation Corrosion Warranty The pressure vessel combustor and exhaust pipes are covered against corrosion form flue gas condensation for a period of five 5 years according to the schedule below This warranty covers nay failure caused by flue gas corrosion however water side corrosion scaling or excessive cycling is not covered Year Prorated Schedule 0 3 100 4 70 5 40 Parts Warranty General Fulton shall be notified in writing as soon as any defect becomes apparent This warranty does not include freight handling or labor charges of any kind These warranties are contingent upon the proper sizing installation operation and maintenance of the boiler and peripheral components and equipment Warranties valid only if installed operated and maintained as outlined in the Fulton Installation and Operation Manual No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority Fulton will not pay any charges unless they were pre approved in
75. ystem 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 4 inch in diameter completely around the male without tabs end of each conduit section or elbow between 1 4 and 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 Installation 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 amp PDWH1000
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