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Fulton pulse boilers

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Luke84

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Discussion starter · #1 ·
I'm a first year service fitter out of local 455 and I ran into a Fulton pulse boiler today at work. I was wondering if anyone could explain to me how these things work. I've never run across one before. I'm pretty new and am trying to gain as much of an understanding of the equipment I'm dealing with as possible.
 
#2 ·
Here is a brochure. if you look at page 5, you will see a pretty good description of how it works. Just remember that on the Pulse, there are effectively no moving parts.
 
#3 ·
Thanks for linking the brochure, meplumber.

As you will read in the brochure, Pulse combustion is maintained through a series of positive and negative pressures, which draw in additional gas and air as required. An initial spark ignites the Pulse process, and the process will sustain itself until the water temperature setpoint is reached. This self aspirating design does not require a blower motor and decreases venting diameter requirements.

If you have more questions, feel free to ask!
 
#4 ·
I have a Pulse question.

What would cause a code 54 "combustion pressure" issue? I have a Pulse that will lock out on this every so often, replaced pressure switch and it ran fantastic for about 2 months, now received a call that it has locked out on this again.

Thanks!
 
#5 ·
71 gibby said:
What would cause a code 54 "combustion pressure" issue? I have a Pulse that will lock out on this every so often, replaced pressure switch and it ran fantastic for about 2 months, now received a call that it has locked out on this again.
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One of the primary causes of code 54 is low gas pressure to the inlet of the gas train. The minimum gas pressure at all times is 7" WC.

Another possible cause could be your venting. How many elbows and what lengths of pipe are on your intake and exhaust?

When was the last time the boiler had a full PM where the gas flappers, air flappers and spark plug were changed?

If you can provide additional details I can try to answer your question better. Alternatively, you can contact our service department directly at (315) 298-7148.
 
#6 ·
71 gibby said:
I have a Pulse question.

What would cause a code 54 "combustion pressure" issue? I have a Pulse that will lock out on this every so often, replaced pressure switch and it ran fantastic for about 2 months, now received a call that it has locked out on this again.

Thanks!
Click to expand...
The most common issue to cause that code, is failure to fire. Now that can be caused by a number of different things.

Start by doing a full service on the unit, including combustion tests. Then calibrate the air switch(not the combustion switch) and see how you make out.
 
#7 ·
Been away for awhile!

As an update I Had (2) Phw-1400 locking out on combustion pressure and found both had the brass orifices that vibrated to the point that the threads had allowed them to lower in the combustion chamber threading (for lack of better words), permitting gas to flow around the orifice on the top side.
Replaced both with brass orifices and all is good thus far.

I think I maybe I should have replaced with the stainless steel version however.?????
 
#8 ·
71 gibby said:
Been away for awhile!

As an update I Had (2) Phw-1400 locking out on combustion pressure and found both had the brass orifices that vibrated to the point that the threads had allowed them to lower in the combustion chamber threading (for lack of better words), permitting gas to flow around the orifice on the top side.
Replaced both with brass orifices and all is good thus far.

I think I maybe I should have replaced with the stainless steel version however.?????
Click to expand...
Sorry for the delay in response, I have also been away on vacation. :cheers:

Yes, the stainless would be a permanent fix. You can contact our service department if you would like to go that route. They would need to know the NB cycles, hours, and site information.
 
#11 ·
HVACguru79 said:
Question Combustion motor assembly on a PHW950CM. What is the easiest way to get the motor out of the black steel box were it resides? It is deffinatly not easy to get to.
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HVACguru79 said:
Also if you have any pictorials of the parts of the PHW-950CM model. That would help.
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Hello HVACguru79, to remove the blower motor on a PHW950CM, the air flapper housing needs to be removed to gain access. The tool needed to remove the blower housing can be ordered through your local Fulton representative. You can find your local Fulton representative by going to www.fulton.com/sales and following the prompts. The Fulton part number of the tool you need is is 8-00-000049.

While there are some drawings and partial cutaways of the Pulse boiler within the brochure and manual, I do not have any pictorials specific to the motor removal.
 
#12 ·
FultonBoiler said:
Hello HVACguru79, to remove the blower motor on a PHW950CM, the air flapper housing needs to be removed to gain access. The tool needed to remove the blower housing can be ordered through your local Fulton representative. You can find your local Fulton representative by going to www.fulton.com/sales and following the prompts. The Fulton part number of the tool you need is is 8-00-000049.

While there are some drawings and partial cutaways of the Pulse boiler within the brochure and manual, I do not have any pictorials specific to the motor removal.
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FultonBoiler congratulation on lasting as long as you had with Fulton, they have a reputation for "hiring and firing" all the time, I was told that very few make it beyond the year mark, you must be really good at it.
 
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#13 ·
valdelocc said:
FultonBoiler congratulation on lasting as long as you had with Fulton, they have a reputation for "hiring and firing" all the time, I was told that very few make it beyond the year mark, you must be really good at it.
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I've been with Fulton for ten years and I do like to think that I'm good at my job, yes. I'm not sure where you get your information, but that reputation is unfounded. The majority of our employees have been here for years. We have a lot of new people these days because we've been growing, expanding departments and creating new positions, but there has been very little turnover.

We actually have a number of new positions open right now which can be viewed on our website: www.fulton.com/jobs
 
#17 ·
targetman said:
It's to bad that Fulton subs out tech support to the local rep.
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Hello targetman, while it's important to us that our reps are able to keep business within their local territories, each representative has been factory trained and is certified to work on Fulton equipment. Fulton also maintains a dedicated in-house service group who respond to service requests and assist reps on-site as necessary.
 
#18 ·
Fulton PHW1400

I have two Fulton PHW1400’s sitting side by side. I’ve had a couple problems with them over the years but as they age the problems become more bothersome and frequent. The service has been done each year and they are in fair condition. Boiler one trips on code 54 daily and boiler two was tripping on fan switch. I heard the fan squealing while trying to run and replace it. Now boiler two trips on code 54 also. Any help is appreciated.
 
#19 ·
Myvz800 said:
I have two Fulton PHW1400’s sitting side by side. I’ve had a couple problems with them over the years but as they age the problems become more bothersome and frequent. The service has been done each year and they are in fair condition. Boiler one trips on code 54 daily and boiler two was tripping on fan switch. I heard the fan squealing while trying to run and replace it. Now boiler two trips on code 54 also. Any help is appreciated.
Click to expand...
Hello Myvs800, do you have any additional information regarding the service you've done (replacement parts, combustion numbers, etc)? More details could assist us in troubleshooting your problems.

Typically, code 54 indicates a combustion problem (poor combustion, bad air-gas flappers, etc). Without additional information, it's difficult to diagnose with certainty, but there are several things you could consider. The problem could be high back pressure on the exhaust (over 2.5” at high fire), or the gas pressure may be dipping below 7” incoming on start up. You should also ensure the fan switch is changing state properly.
 
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