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Instruction, Operation, and Maintenance Manual Fulton Oil Fired

1. Ratings Flame Sensor Ground Earth Ground BEEN Line Voltage Common Neutral Earth G AL Alarm Normally Open FAN Line Voltage Supply L1 220 230 Vac 10 50Hz 10 220 230 240 Vac 5A maximum LD2 220 230 240 Vac 1 mA PV1 Pilot Valve 1 Interrupted 220 230 240 Vac 4A at PF 0 5A 20A inrush Main Fuel Valve 220 230 240 Vac 4A at PF 0 5A 20A inrush IGN 220 230 240 Vac 2A at PF 0 2 Abbreviation Description Ratings F 11 Flame signal 136 220Vac 50HZ limited current R7886 input maximum 50Vdc 230 Vac 15 19 50Hz 10 220 230 240 Vac 1 mA 220 230 240 Vac 1 mA PV2 Pilot Valve 2 Intermittent 120 Vrms chopped 230 Vac 100mA 50 Hz The EC7830A must have an earth ground providing a connection between the base and the control panel or the equipment The earth ground wire must be capable of conducting in event of an internal short circuit fusing 2A fuse or circuit breaker 7830A have a low impedance ground connection to the equipment frame which in turn needs a low impedance connection to earth ground For a ground path to be low impedance at RF frequencies the connection must be made with minimum length conductors that have maximum surface areas Wide straps or brackets are preferred rather than lead wires Be careful to 55 Parts ensure that mechanically tightened joints along the ground path such as pipe or conduit threads or surface
2. g When making gas piping joints use a compound to seal the gas line treads Do not use Teflon tape on gas line threads h The main and the pilot gas pressure regulators must be vented to the atmosphere i After gas piping is completed carefully check all piping connections for gas leaks Use a soap and water solution Caution Some matters used for leak testing are corrosive to certain types of metals Rinse all piping thoroughly with clean water after leak check has been completed j The boiler must be disconnected at the boiler shut off valve from the gas supply piping system when intake gas pressure is in excess of 14 W C k The boiler must be isolated from the gas supply piping system by closing the shutoff cock during any pressure testing of the gas supply piping system at pressure equal to or less than 1 2 PSIG 14 W C 12 Boiler Condensate Tank Description Instruction insulated This can cause C overheating the return system causing a vapor lock There are three blow off valves on the boiler the main valve at the rear of the boiler the water in the pump gauge glass blow off valve and And Blow off Separator water gauge blow off valve The NOTE NOTE boiler blow off valves supplied Where a condensate return tank is to be fitted this should 1 Be vented 2 Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature 3 Vent pip
3. Parts Oil Burner and Ignition Assembly Parts 48 Oil Burner and Ignition Assembly Components Item 1 Part No 2 40 605 2 40 606 2 40 603 2 40 770 2 40 608 2 40 611 2 40 609 2 40 772 2 40 616 2 40 618 2 40 617 2 40 621 2 40 773 Burner Motor 1 3HP 115 230 60 1 1 3HP 230 460 60 3 1 3HP 110 220 50 1 1 3HP 380 50 3 3 4HP 115 230 60 1 3 4HP 230 460 60 3 3 4HP 110 220 50 1 2 0HP 380 50 3 2 0HP 115 230 60 1 2 0HP 230 460 60 3 2 0HP 110 220 50 1 3 0 HP 230 460 50 60 3 3 0HP 380 50 3 The correct part number is located on the burner motor Item 2 Item The correct part number is located on the back of the fan plate Item 4 Part No 2 11 123 5 20 059 5 20 060 2 11 126 2 11 121 Part No 2 30 462 2 30 410 2 30 412 2 30 413 2 30 414 2 30 417 2 30 418 2 30 431 2 30 425 2 30 427 2 30 424 2 30 559 2 30 437 2 30 439 Part No 2 40 086 2 40 087 2 40 088 2 40 089 Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Fan 5 1 2x1x5 8 6 1 4x1 1 2x5 8 7x1 1 2x5 8 7x2x5 8 7 11 16x1 1 2 X 5 8 8 3 8x 1 1 2x5 8 8 3 8x2x5 8 9 15 16x1 1 2x5 8 9 3 16x2 1 2x1 9 3 16x3x1 9 15 16x2 1 2x1 9 15 16x3xL075 9 15 16x3 1 2x1 10 5 8x4x1 Ignition Transformer 120 60 1 240 60 1 120 50 1 240 50 1 RPM 3450 3450 2850 2850 3450 3450 2850 2850 3450 3450 2850 2850 3450 2850 Fuel 2 Oil 2
4. and the 30 BHP make up air opening size is 0 37 M recommended NOTE These measurements are subject to local regulations The installation of exhaust fans in a boiler room is not recommended An exhaust fan or similar equipment can create down draft in the stack or restrict the burner s air supply which will result in poor combustion It is essential that only fresh air is allowed to enter the combustion air System Foreign substances such as combustible volatiles and lint in the combustion system can create hazardous conditions 20 Conventional Venting in accordance with the local fire prevention and control code a The stack should rise continuously to the connection with the chimney and should contain no more than two bends at 45 angles or less If required as the result of space limitations one 90 elbow can be fitted at the back of the boiler There should be two feet of straight horizontal flue before any bends or turns Any alternative stack arrangement must supply 02 04 W C pressure burner off b The total horizontal run of the boiler stack should not exceed 25 of the total vertical rise Except for the condition as a the horizontal flue should be avoided and the horizontal total pipe length must be no more than 4 feet Install n a Appropriate Weather Cap Draft Regulator m If Necessary Horizontal Cleanout Door Description Instruction C The stack an
5. prevention and control code Boilers for which sidewall venting may be utilized are Town gas propane gas natural gas or combustion oil and natural gas sizes 4 to 30HP The following criteria is required for installations using sidewall venting 1 Flue vent piping shall be pitched upward at 1 4 per foot of length Side Wall Vent Termination By Others e Le Description Instruction 2 A U L approved draft fan must be installed to provide sufficient dr aft of 0 02 and 0 04 W C pressure to safely vent the products of combustion 3 The draft fan should be located as close to the flue outlet as possible 4 Draft regulation sufficient to lower the draft to between 0 02 to 0 04 W C pressure may be required The draft regulator s Air Flow Safety Switch U L Approved Induced Draft Fan side Wall Vent By Others must be between the boiler and draft fan 5 The draft fan shall have an air flow proving switch wired in series with the boiler air safety switch 6 The sidewall venting total length from boiler exhaust to termination shall not exceed 35 feet 10 7 m with 4 elbows maximum 27 Combustion Air Intake In accordance with the local fire prevention and control code This shall be applicable only for gas fired vertical units sizes 4 30 boiler horsepower The following criteria are required for installations using combustion air intake assemblies 1 Outside air
6. 11 123 5 20 059 5 20 060 2 11 126 2 11 121 Part No 2 30 407 2 30 410 2 30 412 2 30 414 2 30 418 2 30 421 2 30 425 2 30 437 Part No 2 40 082 2 40 083 2 40 084 2 40 085 Part No 2 11 112 2 11 075 2 11 113 7 20 090 7 20 092 7 20 074 Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Scroll Casting Burner Fan 5 1 2x1 1 2x5 8 6 1 4x1 1 2x5 8 7x1 1 2x5 8 7 11 16x1 1 2 X 5 8 8 3 8x2x5 8 8 3 8x2 1 2x1 9 3 16x2 1 2x1 9 15 16x3 1 2x1 Ignition Transformer 120 60 1 240 60 1 120 50 1 240 50 1 Air Deflector Air Deflector Air Deflector Air Deflector Air Deflector Air Deflector Air Deflector RPM 3450 3450 2850 2850 3450 3450 2850 2850 3450 3450 2850 2850 3450 2850 Fuel Propane Natural gas Propane Natural gas Propane Natural gas Propane Natural gas Propane Natural gas Propane Natural gas Propane Natural gas Propane Natural gas Hp 4 15 4 15 4 15 4 15 20 30 20 30 20 30 40 60 40 60 40 60 40 60 80 100 80 100 Hp 4 15 20 30 40 60 80 100 Hz 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 50 60 HP 4 10 9 5 15 20 30 Parts Hp 9 5 10 15 20 30 40 50 60 80 100 40 60 80 100 53 Continued Item 6 Item Item Item 10 Item 11 Item 12 13 14 15 Part No 7 20 050 7 20 051 7 20 078 7 20 052 7 20 023 7 20 054 7 20 055 7 20 265 7 20 056 7 2
7. 60 50 93 02 12292 156 15 186 05 243 51 29221 358 61 413 97 Natural gas m h 4 EUH EUN 11 11 nas 18 1851 23 79 79 36 36 58 834 34 ET 41 7316 16 0576 76 114 11491 ETE 22 176 87 wem RERSEEIBEE Connection size 76 dE ie A eA REA EAR ne Motor HP 2850RPM 50CY 1 3 1 3 1 3 13 13 34 13 34 1 2 5 2 15 2 2 3B 3 4 4 4 4 Electric Power Requirements In Amps 220V 50CY 1 Phase 35 ala e e P 380V 50CY 3Phase f t t l s7 sa s7 46 46 e2 s Control voltage 220V 500Y 1 Phase E Notes All ratings at 212 degree F 100 C Fuel consumption based on Light oil 11200 kcal kg propane gas 22500kcal m Natural gas 8900 kcal m Town gas 3500 kcal m Apply IRI and CSA standard time 2 inch 50mm Description Instruction 10 Description Instruction Dimensions and Weight Boiler He 4 6 m as 20 s a so c so w 10 Height and Width A Height of Boiler i 47 57 63 69 72 82 73 5 87 93 93 99 117 117 mm 1194 1448 1600 1753 1829 2083 1867 2210 2362 2362 2515 2972 2972 B Boiler height with Trim and fuel train assembly IN 80 5 86 5 92 5 106 5 36 mm KE E KE EJ KE 2591 2388 KS KE EX E E 3582 C Overall Depth Stack IN 136 to Burner Fan Housing mm P ES ES FA FA 1702 1854 ES EA FAX EA 3395 D Boiler Diameter IN 26 26 28 30 55 63 68 76 76 5 mm 1170 1400 1400 1400 1588 1740 1936 1943 mod m STS SEE See a with water column m
8. Oil 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb 2 Oil Comb Hz 60 Hp 4 15 4 15 4 15 4 15 20 30 20 30 20 30 40 60 40 60 40 60 40 60 80 100 80 100 Hp 4 15 20 30 40 60 80 100 50 60 60 50 60 50 60 50 60 50 60 50 60 50 Parts Hp 10 10 15 20 15 20 30 30 40 50 40 50 60 60 80 100 80 100 49 Continued Item Part No 5 7 20 080 7 20 082 7 20 084 7 20 086 Item Part No 6 2 30 048 2 30 050 2 30 052 2 30 054 2 30 056 2 30 057 2 30 058 2 30 059 2 30 060 30 150HP require two Item Part No 7 2 30 130 2 30 129 Item Part No 8 2 30 134 2 30 135 2 30 127 Item Part No 9 2 40 221 10 2 20 007 11 2 40 161 Item Part No 12 4 30 010 4 30 012 2 30 191 13 2 30 190 2 30 039 Item Part No 14 5 20 063 5 20 008 5 20 009 Item Part No 15 5 20 065 5 20 066 Air Deflector Air Deflector Air Deflector Air Deflector Air Deflector Oil Nozzle 1 20 GPH 80 1 65 GPH 80 2 25 GPH 80 3 00 GPH 80 4 00 GPH 80 5 00 GPH 80 6 00 GPH 80 8 00 GPH 80 10 00 GPH 80 13 00 GPH 80 Magnetic Oil Valve Magnetic Oil Valve 115V Magnetic Oil Valve 230 Oil Pump Oil Pump 2 oil Oil Pump 2 oil Oil Pump 4 to 6 oil Flame Detectors Cad Cell With Holder Cad Cell Adaptor Scanner for 7800 Series Couplings Coupling Fan to Oil Pump Coupling Fan to Oil Pu
9. and tighten in position Check for CO and Oz level 6 Oil Pump Check for clogged strainer or filter Maintenance Continued 7 Draft Check draft with a gauge Draft should be a 0 02 to 0 04 W C with burner off or 0 04 to 0 06 when operating 8 Dirty flue Check flue for carbon buildup or blockage Clean flue passages with brush 9 Negative Room Make sure no exhaust fans are running in the boiler Pressure room Burner Back Fire 1 Refractories Check refractories to see ifthey are cracked or broken in pieces Replace as necessary 2 Ignition Electrode Check electrodes for carbon build up and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 3 Oil Valves Check for leaking oil valves and replace Poor Combustion 4 Draft Check draft with a gauge Draft should be a 0 02 to 0 04 W C with burner off or 0 04 to 0 06 when operating 9 Negative Room Make sure no exhaust fans are running in the boiler Pressure room 6 Oil fittings Check for all the inlet of oil fittings if there is air mixed if found tighten Check if the inlet is limited if it is replace lines and distance from tank to boiler Boiler will not maintain 1 Oil Supply Check oil level in supply tank to be sure it is not pressure clogged nozzle Clean or replace Check oil filter below intake line Fill tank with oil Check for cl
10. as necessary 3 Ignition Electrode Check electrodes for carbon build up and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace Check for clogged nozzle clean or replace 5 Transformer Check voltage between pilot terminal neutral at terminal block to be sure transformer is being powered 6 Cad Cell Check for ignition interference Check for too small of EE an orifice in scanner nipple 7 Flame Rod Adjustment Check flame for carbon buildup and clean if or UV Scanner necessary Check flame rod adjustment via a display module Flame signal should be 5VDC Check for cracks in porcelain If found replace Check for dirt on flame scanner and clean Check for proper location of detector 8 Air switch Check for bad air switch by jumpering the two air switch leads at the terminal block If the boiler starts and runs with these terminals jumpered the air switch should be replaced Poor Combustion 1 Refractories Check refractories to see if they are plugged with soot TMMM broken i pieces Clanorrephosas necessary 2 S S Ring Check to be sure ring is present and fits tight against ma S PESAS SN 3 Oil nozzle Check for clogged nozzle Clean or replace 4 PrimaryAir adjustment Check air adjustment Air may be blowing flame away from flame sensor 5 Secondary Air Check main air adjustment to see if it is loosened up Adjustment Adjust as necessary
11. assembly and Maintenance or the boiler shell Manual reset of the low water relay is required Recommended Monthly Maintenance Schedule WARRING Make sure main power switch is off before starting work a Clean the water gauge class CAUTION Do not clean the gauge or gauge glass while pressurized or in operation 1 Clean the water gauge glass using a commercial non abrasive glass cleaner Use diluted acids such as hydrochloric muriatic acid when regular cleaners do not seem to work Do not use wire brushes or any other abrasive materials which could scratch the glass If any leakage is evident replace the gasket ev Clean glass replace gasket if leaking 2 Fit the gauge glass protector for water level column b Clean water pump strainers c Check scanner or flame rod and ignition electrode d Check starter contracts Burned or pitted contacts should be replaced Do not use sand paper or file to clean e Clean water traps and strainers in fuel lines f Check operation of all steam traps on condensate return system 39 g Remove brass pipe plug at the cross connection below water column and clean nipple into boiler Boiler must be cold and water level below pipe Recommended Semi Annual Maintenance Schedule a Cleaning the gas burner assembly 1 Oil Clean fan blades oil the motor Replace the fuel oil filter and clean the oil pump strainer Remove clean and adjust the oil
12. intake inlet shall be equipped with a vent cap in order to prevent flame blow out from excessive wind This vent cap shall have a minimum cross sectional opening equal to an 8 inch vent pipe 2 All intake ducting shall have a cross sectional area equal to or greater than 50 square inches 3 A mesh screen shall be affixed to the air inlet with openings of approximately 1 2 x 3 4 4 The total length from outdoors to the boiler intake shall not exceed 35 feet 10 7 m with four elbows maximum Corrosion of flue pipe a In the case of a combustion flue pipe acid may develop over a long period of time per the following process Chlorine containing gases such as halocarbon refrigerants carbon tetrachloride trichloroethylene when drawn into combustion air are broken down into elemental chlorine gas which exits up the flue pipe If the flue pipe is cold as it would be if the combustion process had been off for some time the water vapor condenses in the flue pipe during the first few minutes of ignition and the chlorine in the combustion gas dissolves in the water forming hydrochloric acid As the Description Instruction combustion system flue line increases in temperature the water vapor no longer condenses because the flue temperature is above the dew point of the combustion gas The combustion gas then dries out dehydrates the hydrochloric acid solution leaving behind dry chloride salt b When the next
13. is concentrated Chlorides Chlorides are involved in most cooling water 18 corrosion cells Other factors being equal it can be assumed the higher the chloride content the more corrosive the water When pits or cracks occur on stainless steel or other metals chlorides are always suspect High chloride levels can cause severe corrosion Corrosion from chlorides can be controlled by increasing the amount of corrosion inhibitor or changing to a more effective inhibitor Oil Oil is not a natural constituent of boiler water still it can frequently enter a system through leaks in a condenser or other heat exchanger Oil can also enter a system through the lubrication of steam driven reciprocating equipment Whatever the source the presence of oil in boiler water is undesirable Oil can act as a binder to form scale In high heat transfer areas oil can carbonize and further contribute to the formation of scale Foaming is one indication of oil in boiler water Its presence can also be confirmed by first shaking a bottle containing boiler water If oil is present foam will result To ensure the foaming is being caused by oil add a small amount of powdered activated carbon to the bottle containing the boiler water and shake Little or no foam will appear if the foaming is caused by oil Often oil in boiler water will originate in the condensate This contaminated condensate should be directed to the sewer until t
14. linkage arms To adjust the Panel Box for Modulating Gas Fired Boilers linkages unscrew the swivel collar and move the linkage rod in the appropriate direction h Modulating burners will have a proportioning pressure control in 29 Gas Burner Set up for Boilers Equipment with High Low Off a A gas fired burner equipped for high low off firing is available as an option on Fulton gas fired steam boilers for 30 150 HP units only b Boilers that have a high low off firing rate have a linkage between the high low gas valve and equipped with a spring return c The linkage will be disconnected from the gas valve shipment d Mount the gas train on the pipe nipple of the burner plate with the gas train inlet directly facing over the panel box Reconnect the linkage from the primary air gate to the high low gas valve e The end of the linkage arm that does to the gas valve will have a swivel collar should be centered This setting was based on factory test fire conditions f Combustion analysis should be done at the installation to make any changes to insure proper combustion characteristics g To adjust the linkage unscrew the swivel collar and move the linkage rod in the appropriate direction The high low off configuration comes with two operating pressure controls h Set the low operating pressure control to approximately 6096 of your desired set point and the main operating pressure control to your desired set p
15. nozzle and the electrode assembly 2 Disconnect the gas head from the burner by disconnecting the union Remove the burner plate screws For 4 15HP boilers with scanner disconnect scanner from burner plate If using flame rod then check the equipment reset the burner assembly and check the setting of flame scanner 3 Check the combustion efficiency of the burner and adjust if necessary 4 Clean probe on top of boiler shell and probes in water column These must be no pressure on the boiler during the removal of the probes 5 Check refractories for soot or breakage and inspect the stainless steel ring 6 With the boiler under no more than 15PSI pressure check that the steam safety valve is operating by lifting the lever b Drain condensate tank and clean tank by flushing with hose Check float valve operation c Check electrical controls and motors for correct operation d Check water pump for correct operation e Shut off the boiler completely and drain f Remove the hand holes and inspect the interior of the vessel for scale or sludge deposits The amount of deposits will indicate the efficiency of the water treatment being used The frequency of the inspection will depend on the condition of the water side of the boiler titriidd dl Inspect hand holes for scale or sludge buildup g Replace hand hole gaskets using the following procedures 1 Remove the hand hole assembly using a 1 1
16. of maintenance outlined in this section should be adhered to WARRING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be disconnected Procedure for Cleaning Water Probes Clean probe on top of boiler shell and probes in water column Make sure there is no pressure on the boiler during the removal of the probes Remove one probe clean with very fine emery cloth and replace it before removing another to assure no probe mix ups that would change the control functions For replacement purposes installed probe lengths are indicated in the chart below For a universally adaptable plug and probe which can be cut to length in the field to fit all boilers Az7 1 4 184mm Bz9 1 4 235mm C 11 1 4 286mm D 17 1 8 435mm For 4 HP boilers only water column probes are 2 shorter Maintenance 36 Flame Rod Adjustment for Fulton Gas Fired Boilers a The flame rod adjustment is made by loosing the lock nut and turning the porcelain portion of the flame rod clockwise or counter clockwise Whenever a flame rod is moved care should be taken to ensure that the flame rod does not ground out by touching the metal surface of the blast tube assembly A keyboard display module can be used to determine proper signal response t is necessary to establish pilot so that the main gas valve wil
17. the burner scroll which controls the amount of the air that is delivered over the oil nozzle This should be adjusted to keep the fire from backing up into the blast tube i Make sure the secondary air damper is locked j Lock into position the main air control shutter k After the oil has been ignited in the burner it will be controlled through an on off cycle by the pressure control in the panel box which should be adjusted to 80 100HP Left 130 150 Right Fuel suit the boiler application Oil Siemens series Control panel 27 Gas Burner Set Up a Open the manual gas cocks on the pilot and main lines of the gas head b Switch on the main power to the burner The water level relay is equipped with a manual reset Depress the button on the box c The flame programmer is the main control in the panel box The programmer in conjunction with a sensing device either a flame rod or a UV scanner supervises the ignition sequence proves the flame is satisfactory and finally monitors the established flame Should any fault occur either during the ignition sequence or during normal running the programmer will immediately go to lock out and the burner will shut down d When the pilot flame is established the flame rod or ultra violet scanner senses the voltage which is created in the flame between the flame rod and the gas nozzle ground This signal is transmitted back to the flame programmer which opens t
18. to the boiler through the steam safety valve opening 4 The mixture of washing soda to water is as follows Boiler Size Soda 4 6 454g 10 15 908g 20 30 1362g 40 50 1589g 60 1816g 80 22709 100 130 31789 150 4250g 5 Replace the steam safety valve 6 Fill the boiler with water Water column is about center in the water gauge glass 7 Generate 15 PSI 1 054kg cm2 of steam and shut off the boiler Allow this hot solution to remain in the boiler for 10 minutes 8 Drain and flush the boiler twice with fresh water 9 To remove all the oil and dirt from the main steam and the condensate return lines allow the returns to go into a floor drain or a safe discharge point for the first week of operation CAUTION Do not store halogenated 23 Description Instruction requirements Review local treatment Water analysis should hydrocarbons near or in the codes be made by a competent water boiler room l 7 As a final checkpoint again treatment concern and their In general ensure that the boiler water treatment recommendations should be area is in conformance with Here we emphasize the followed established boiler room importance of proper water 3 Inject soda water 4 Make boiler water level at the position 5 Keep boiler pressure for 10 Of arrow minutes at 15PSI 24 Operation Operation well as during the non operating period of the boiler Starting the Boiler Stop Make sure you
19. tone line is feeding two boilers 6 If necessary fit soft connection pipe for circling pump and expanded tube must be located between the high level water tank and the return water intake 58 Warranty Warranty 3 Year Conditional Warranty On the Fulton Boiler Pressure Vessel Fulton Boiler Works Inc will repair or replace any Fulton pressure vessel which Within three 3 years of the date of shipment from factory is found to be defective in workmanship or material provided this equipment is installed operated and maintained by the buyer in accordance with the Fulton instruction manual and approved practices and that the water quality used in the system has been regularly checked to meet the standards for ideal and proper boiler feedwater during the warranty period This warranty does not cover damage of failure that can be attributed to corrosion including oxygen pitting scale or dirt accumulations or to low conditions Follow feedwater and recommended treatment specifications as detailed in section 1 of the instruction manual shipped with your boiler as well as maintenance procedures as listed in section 4 This 3 year warranty applies only in the continental U S A and Canada The warranty does not include labor charges of any kind In the event a failure is reported Fulton will require an analysis of the boiler feedwater to determine that acceptable water conditions are present at the installation site as well as documentatio
20. wire to drop it flat on the holding clips If the refractory will not tip it may have to be removed and again rounded and beveled i Install the top refractory in the same manner as the bottom refractory When installed the outer edges must be sealed with insulcrete a castable refractory mix available from the Fulton factory It is not necessary to reinstall the shipping clips j Install the stainless steel combustion ring burner assembly and clean out plug k Normal operation can be resumed immediately Gas Head Assembly Gil Nozze Assembly Stainless Steel Combustion Chamber Ring supporting Clips Holding Clips for Shipping Stainless Steel Supporting Clips Top Castable Refractory Bottom Castable __ Retractary Halding Clips Stainless Steel Supporing Clips 38 Recommended Maintenance Schedule Daily a The following procedures should be carried out daily They are designed to prevent the build up of scale silt or sludge in the bottom of the boiler and in the in the pipes leading to the water gauge In addition to these procedures the advice of a water treatment supplier should be sought and followed b Blow down the boiler each morning by starting the boiler and generating not more than 10 PSl lb in 2 of steam Turn on tap water to blow off separator then open the boiler blow off valve for approximately 10 seconds then close the valve Shut off tap water to blow off separ
21. 0 057 7 20 058 7 20 059 Part No 2 30 118 Part No 2 40 161 2 20 020 Part No 5 20 019 5 20 007 5 20 055 5 20 013 5 20 018 5 10 398 5 10 399 Part No 5 20 017 5 20 012 5 20 011 5 20 066 Part No 2 20 021 2 30 149 5 20 021 2 12 014 Gas Orifice Propane 7 20 030 7 20 061 20 062 7 20 033 7 20 064 20 065 7 20 275 20 066 20 067 20 068 20 069 Air Switch Scanner Scanner for 7800 Series Flame Rod Burner Plate Burner Plate Burner Plate Burner Plate Burner Plate Burner Plate Burner Plate Burner Plate Air Gate Air Gate Air Gate Air Gate U K Air Gate Electrode Parts 11 Ignition Electrode Ignition Electrode Holder Ignition Electrode Holder Pyrex Plate Glass 1 Parts HP 9 5 10 15 20 30 40 50 60 80 100 HP 4 100 HP 5 100 4 30 HP 6 10 9 5 15 20 30 60 80 100 HP 4 10 15 20 30 40 100 HP 4 100 4 20 30 100 4 100 54 Parts EC7830A Installation and Wiring N EO dr Water Level Relay 4 50HP 1 phase Motor Contactor Starter Standard Overload 3 Phase 60HP T ad 3 phase Contactor elay phase Overload Standard for Feed Water 3 phase Available Pump Motor ON 4 50HP As Option Flame Safe p Power Guard Burner On off Switch Control HighLimit Low Limit 7 BEN q Pressure With Manual Reset Pressure Control Operating Pressure Control Wiring EC7830A Terminal No Abbreviation Description
22. 0 100 BHP 4 100 9 5 BHP 4 100 9 5 4 100 4 100 4 100 4 100 4 100 9 5 BHP 6 100 6 100 6 100 6 100 4 100 4 100 4 100 Parts Located In Boiler 14 57 Sketch of Layout for Boiler Room of 4 150HP Fulton Oil Gas fired Steam Boilers Feedwater Inlet Gas Inlet Connection Blowdown Cooling Pool Water Treatment I i Equi quipment l i i Chimney l 5 i Ne Downard Gas Inlet P Blowdown Strainer Lower U Tube for Test Pressure Safety Valve m Drain Pipe f Switch Box S Control Room Note 1 This layout is a reference for Fulton oil gas fired steam boilers Parts 2 The boiler room must be in accordance with the local code and related fire prevention and control code and the oil tank should fit with firewall 3 There should be set two venting of up and down according to the size of the boiler room 4 The chimney can be installed at the roof after it is extend the roof or the wall in accordance with the manual 5 Gas intake pressure must be in accordance with the rated requires for boiler Otherwise set pressure reducing valve or pressure regulator valve at he outlet of filter pump inlet pressure is no more than 10 of mercy including oil filter and resistance of line pump inlet height should be higher 500mm than outlet but no leakage and air resistance occur and set resistance turning check valve on lines especially when
23. 1091 1244 1448 1448 1448 1702 1905 2108 2146 nulalslalals Eli een mm 407 ee IUE EE ERE AE AEHIE mm 1070 1320 1473 1600 1675 1867 1651 2007 2159 2423 2423 2723 2794 Minimum Clearance H The least height Required for Replacing burner in 114 157 mm 1828 2083 2184 2337 2438 2692 2642 2896 3149 3200 3277 3835 3988 ni Fara RAGS mm 1041 1041 1041 1041 1041 1041 1041 1041 1041 1041 1041 1041 1041 cn os ois os os ois on as os ss ms os or mm 915 915 915 915 915 915 915 915 915 915 915 915 915 wor Gel HHHHFRHRRFRFRE LITERS 53 61 91 148 292 643 835 927 1022 1419 2195 3317 3423 REI LEE IE IEEE HIE IE IE DE LE HEIE Approx Shipping Weight KG 640 770 910 1035 1545 2170 2905 2963 3305 4770 5270 6773 7060 Note Z m 3 UJ Clearance for boilers below 50PSIG are 18 457mm on sides and rear of boiler 11 Locating the Boiler a The boiler should be located in dry surroundings on a level base making sure that there is sufficient room around the boiler to enable the operator and or the maintenance engineer to gain access to all parts of the boiler Check location for ease of water supply and electrical connections b Place the boiler on a noncombustible floor with clearances to unprotected combustible materials including plaster or combustible supports C It is necessary to have the sufficient clearance from the floor to the ceiling for removal of the burner The Fuel Oil Supply a Be sure tha
24. 4 tee handle wrench or drive socket wrench 2 Remove the old gasket and thoroughly clean the surface on the boiler and the plate 3 Fit the hand hole assembly as follows Maintenance a Place the gasket on the hand hole plate and ensure that it is seating correctly Do not use any grease lubricant or adhesive b Position the plate in the boiler Set the yoke and tighten the securing nut sufficiently enough to provide a snug fit Verify the position of the plate in the boiler then make it hand tight and then snug with wrench about 1 4 turn Do not compress excessively Illustration shows correct pressure on gasket C If the gasket leaks while pressure is being built up tighten only enough to stop leakage Never tighten more than necessary to prevent leakage Excessive tightening may shorten the life of the gasket Illustration shows over compressed gasket d Refill the boiler with fresh water NOTE After a new Fulton Boiler has been in operation for several months pieces of burned metal 40 will be found in the space at the bottom of the boiler These pieces of metal are the remains of a light gauge metal form which was used during manufacture for forming the boiler insulation This is a normal condition and does not affect the efficiency or the life of the boiler in any way Recommended Annual Maintenance Schedule recommended maintenance a Repeat the semi annual sche
25. DUC TIN INDUSTRIES LIMITED COMPANY Head Office 6 16 Fourth Quater Tan Chanh Hiep Ward Dist 12 HCMC Rep Office 8 10 Nguyen Ba Tuyen Str Ward 12 Tan Binh Dist HCMC Tel 08 6297 3207 Fax 08 6297 3209 Hotline 0982 455 456 Email info ductin com vn Website www ductin com vn Serial Number Model Number Contract No Date Duc Tin Industries Instruction Operation and Maintenance Manual Fulton Oil Fired Gas Fired Steam Boilers 4 HP to 150 HP This manual is provided as a guide to the correct operation and maintenance of your Fulton Oil Fired Gas Fired Boiler and should be permanently available to the staff responsible for the operation of the boiler These instructions must not be considered as a complete code of practice nor should they replace existing codes or standards that may be applicable The requirements and instructions contained in this section generally relate to the standard Fulton Oil Fired Gas Fired steam Boiler When installing a packaged unit this entire section should be read carefully to ensure that the installation work is carried out correctly Prior to shipment the following high standard tests are made to assure the customer has the highest quality of manufacturing a Material inspections b Manufacturing process inspections c ASME welding inspections d ASME hydrostatic test inspection e Electrical components inspection f Operating test g Fi
26. RE One BRUWAS ICTS ie enya Primary Air Adjustment Is Located At Fan Housing Face Secondary Air Adjustment Procedure For Fulton Gas Fired Steam Boilers a The secondary air control adjustment is located on the top right hand side of the burner assembly This damper type air controller is used to introduce air to and through the blast tube of the burner The purpose of the primary air adjustment is to proportionately divide the air to the center or outer fire chamber By moving the damper closed the air is forced to the outside of the fire chamber with less air going down the blast tube area By pulling the damper open more air is forced down the blast tube and less on the outside wall of the deflector face and fire chamber It is important in the combustion process to maintain proper air mixtures between the outer surface Secondary Air Adjustment for 30 150HP and center of the blast tube area On most boilers the damper is locked in a wide open position However if it is necessary to close the damper care should be taken to close the damper slowly and no more than 1 4 of the distance of the swing of the damper assembly b A visual examination down the blast tube should reveal that no heat flames or fumes are backing up through the burner plate area If they are the damper must be opened up once again Failure to remove the flame or gases from the blast tube area will result in severe backfires as well as
27. ator Blowdown boiler darily shown is the blowdown Y Valve NOTE If the boiler is being operated automatically on a time clock the blow off operation may be done once during the working day and once at the end of the day when at 10 PSIG or less c Blow down water column each morning when boiler is at 10PSI by opening the water column and the water gauge blow off valves for approximately 5 seconds then close the valves d If the feed water is being treated by compounds make sure that this treatment is carried out carefully and according to the manufacturer s instructions NOTE Fulton recommends that the water treatment should be added between the pump and the boiler e When first starting the boiler each day make sure ignition and burner are working properly f Check water level in slight glass g Check to be sure feed water pump is working h For float type water level control blow down float chamber Recommended Maintenance Schedule Weekly Check that the low water cut off relay is opening correctly in the following manner 1 Make sure that the boiler is cool with little or no pressure showing on the steam pressure gauge 2 With the burner operating open the boiler blow ff valve When the water drops below the required level note the level in the water gauge glass the burner should shut off this is when the water level falls below the low water electrode in the water column
28. cause premature failure of electrodes flame rods and other burner components Blast Tube Viewing Port 3l c A visual inspection down the view port should also show the fire completely covering the furnace walls If the fire is tunneling down or is not to the outside wall of the furnace the efficiency will drop off Close the secondary air damper until tunneling stop Boiler control a Flame Safeguards Burner Control this is the main control in the panel box The programmer in conjunction with a sensing device flame rod or an ultra violet scanner supervises the ignition sequence proves the flame is satisfactory and finally monitors the established flame Should any fault occur either during ignition sequence or during normal running the programmer will immediately go to lock out and the burner will be shut down b Low Water Cut off probe type Cuts off the units when water level is too low after a 3second time delay to avoid nuisance shut downs As a standard feature Fulton boilers are equipped with ASME CSD 1 code controls which include a manual reset feature on the burner low water cut off relay and ASME CSD 1 Code controls also feature an independent second low water reset button and the boiler will start CAUTION Do not tamper with the safety features of the water safety cut out c Pressure Relief Valve limits maximum operating pressure of the boiler d Operatin
29. cold start up occurs the process repeats except that more and more chloride collects and concentrates along the flue As the quantity of chloride increases it does not dehydrate completely as the flue heats up and a corrosive poultice develops which attacks the steel and will also attack the boiler C Concentration levels of only a few ppm of chlorine containing compounds in combustion air can produce serious corrosion over long periods of time High chlorine containing compounds such as carbon tetrachloride or perchloride would be prime suspects Installation Check Points 1 Make sure all piping connections are complete and tight 2 Make sure the pressure controls are adjusted properly 3 Make sure all electrical connections in the control panel box the water column and elsewhere are secure 4 Make sure the door in the boiler room is closed Combustion air contaminates can cause damage to the boiler jacket and stack NOTE After installation is complete and prior to operation the pressure vessel should be cleaned Cleaning the Pressure Vessel a After the boiler has been installed and before it is placed in service it is advisable to purge the pressure vessel of any oil film dirt or other impurities Clean the pressure vessel as follows 1 Isolate the boiler from the system by shutting off the main steam valve 2 Remove the steam safety valve 3 Mix washing soda with water r and pour it in
30. d carbonates break down to form carbon dioxide in steam which is a major factor in the corrosion on condensate lines High alkalinity also causes foaming and carries over in boilers Both foaming and carry over cause erratic boiler operation When foaming occurs an anti foam should be added or increased The reason for the high alkalinity should be determined It may result from lack of sufficient blow off Pretreated makeup water and condensate should also be checked Quite often the source of alkalinity is an overdose of alkaline internal water treatment chemical pH pH is a measure of the degree of acid or base of solution Normal pH ranges of 6 5 9 0 will have little influence on the corrosion rate of cooling waters If for some reason pollution etc the pH is lowered into the acid range increased corrosion can be expected The solution lies in determining the cause of the low pH and correcting that condition A low pH can result in corrosion of metals while a high pH can result in scale formation In order to control boilers and equipment used for the external treatment of make up water it is essential that reliable pH measurements be made Phosphates Ground or surface waters seldom contain large amounts of phosphates If present it generally indicates fertilizer runoff or pollution Phosphate from raw water can be the cause of scale problems in open recirculation cooling water systems after the water
31. d chimney must be constructed from material that is rated for 532 degrees C operating temperature Check all local codes for exact requirements d Adequate provision must be ma de for the support of the weight of the chimney and stack to avoid having too great a load imparted to the flue outlet connection of the boiler e The proper flue size and draft control is most important for proper burner operation The flue must be as large or larger than the outlet on the boiler Avoid flue piping too long and elbows too much by placing the boiler as close as possible to the chimney f A mechanical draft regulator may need to be installed in the flue outlet Do not install the draft Support As Mecessary As Stagg Entra A md Horizontal un This Distance Must Not Exceed 25 Of Total Rise Any Structure Expansion Joints ee oe Draft Regulator E If Necessary i regulator prior to the first turn of the flue g The installer should check the draft with a meter at 0 02 0 04 W C pressure with the burner off and 0 04 to 0 06 W C pressure with the burner on BHP Boiler Flue Size Inches Millimeters 4 6 152 6 6 152 10 6 152 15 8 203 20 10 254 30 12 305 40 12 305 50 12 305 60 12 305 80 14 356 100 14 356 130 16 400 150 16 407 Minimum 5 Above ithin 30 Baffle Cleanout Door 21 Exhaust Side Wall Venting In accordance with the local fire
32. d the feed water system to be attacked by the water in amanner described as pitting The pits that are produced can vary from tiny depressions to holes large enough to penetrate the boiler metal and are usually covered with tubercles of iron oxide Once pitting starts it may be extremely hard to arrest Pitting can proceed at a surprisingly rapid rate and can occur not only in the boiler proper but also in pre boiler equipment such as economizers feed water heaters and feed water lines Sodium Sulfite Its purpose is to chemically remove the dissolved oxygen left in the feed water Sodium Sulfite reacts chemically with dissolved oxygen producing sodium sulfate Since it is desirable to remove dissolved oxygen from the feed water before it reaches a boiler Sodium sulfite is best introduced continuously at some suitable point in the feed water system the storage section of the feed water heater six inches below the water line Chemical residual control is based on the maintenance of a specific excess of sodium sulfite in the boiler water The essential requirement being to maintain in the feed water at all times slightly more than enough sodium sulfite to consume all of the dissolved oxygen When sodium sulfite is not fed continuously protection of the boiler against oxygen attack must depend on the reserve of sodium sulfite that is present in the boiler water In this case it Description Instruction is imp
33. dule Remove burner and flue cover plate 1 Remove burner and flue cover b Dirty flues can cause air flow plate restrictions resulting in poor combustion and loss of efficiency Clean Flues as Follows Wire brushing the flue passages 2 Wire brush flue passage Test Pressure Tapping Ignition Flame Rod Electrode e B Ignition j Electrode Holder Burner p gd Orifice Fipe 1 Remove the burner ar cover plate Grounding Fins Maintenance 3 Remove clean out plugs at lowest part of unit and clean the bottom of combustion chamber Removing clean out plugs 4 Remove all soot from the top and from the clean out plugs at the bottom with a vacuum cleaner 5 Replace clean out plugs carefully so as not to damage insulation and replace burner and flue cover plates c Flush boiler out if necessary See Section 2 for proper procedure for Cleaning the Pressure Vessel d Provide annual inspection by a qualified inspector Gap to Pipe 3 16 1 16 f pF rd al Gap to Pipe 3 16 1 16 41 Maintenance Trouble shooting a The following trouble shooting guide will assist in the diagnosis and the correction of minor field problems It contains instructions and isolate possible troubles which occur during normal operation It should be used in conjunction with the wiring diagram b The following lists the most common troubles that may occur on the Fulton oi
34. e Description Instruction 1 2 12 5 1 2 12 5 BHP Milimeter 2 When feeding the boiler using a return system the feedwater makeup pressure should not exceed 40 Ib in A pressure reducing valve should be installed ahead of the return tank above this pressure 3 It is important that all piping be lined up and not forced into place It is recommended that you begin piping at the pump if line the piping at reversed direction particularly if the last piece is cut too short or long the pump will be forced to meet the pipe and strain or distortion will result 4 Do not use the pump as a piping support t is critical that the pipe be independently supported near the pump so no stain will be transmitted to the unit 5 Connect the feed water stop valve to the water pipe at the rear of the boiler and pipe it to the return System 15 The Water Column Install the piping from the water column and water gauge glass to a safe blow off point Water Gauge amp Gauge Glass Installation Instructions Note Only properly trained personnel should install and maintain water gauge glass and connections Wear safety glasses during installation Before installing make sure all parts are free of clips and debris Note Keep gauge glass in original packing until ready to install 1 Verify the proper gauge has been supplied 2 Examine the gauge glass and packing carefully for damage before installation Do no
35. e correct level in the boiler This level is approximately the center of the water gauge glass WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be disconnected CAUTION Do not tamper with the safety features of the low water safety cut off CAUTION When stopping the boiler for any extensive repairs shut off main disconnect switches on both the boiler side as well as the feed water side NOTE To ensure that your Fulton Steam Boiler is kept operating safely and efficiently follow the maintenance procedures set froth in Section 4 of this manual NOTE The flame scanner is located on the outside edge of the burner top plate for 20HP 150HP NOTE If the boiler is being operated automatically on a time clock the blow off operation may be done once before boiler is operated during the working day and once at the end of the day when at 10 PSIG oafety Warnings Cautions amp Notes NOTE Fulton recommends that feed water treatment should be performed before it is added into the boiler WARNING Make sure main power switch is off before starting work CAUTION Do not clean the gauge or glass while pressurized or in operation NOTE After a new Fulton Boiler has been in operation for several months pieces of burned metal will be found in the space at the bottom of the boile
36. e regulator type 220V 10 Yes No Installation Date Place Manage type Used to This boiler is instead of the old new Oiland Gas Warranty electric Please read carefully the user manual from Fulton and operation and maintenance must be in accordance with this manual Note The inlet voltage of electric panel box must be kept at the ranges of 200V 10 otherwise the controller can be damaged and the constant voltage equipment is advised If the boiler draft and panel box both use 220V 1 use the 3KW 220V constant voltage with high accuracy If the draft use 380V 3 but panel box use 220V 1 then use the 1KW 220V constant voltage with high accuracy e Weare not in charge of the problems caused by that the feed water is not as the manual requires such as no soften water equipment Please install fuel lines filter otherwise the user bear themselves 61 Warranty Guarantee Card of Fulton Boilers Boiler Type Steam Hot Water Oil Gas Oiland Gas electric Boiler No Company Address Linkman Tel Postcard Purchase Date Distributor Address and Tel Direct Maintenance charger Oil and Gas Filter Water Treatment Equipment Yes Type No Yes Type No Voltage fit constant voltage equipment type 220V 10 Yes No Installation Date Place Manage type Used to This boiler is instead of the old new Thanks for purchasing Fulton Boiler please a
37. e should not be downsized this may cause pressure build up in the condensate tank To be sure that the blow off separator used is in accordance with the local codes If there are any questions consult with Fulton Company a Make sure two check valves are installed between the boiler and pump one check valve is pre fitted b Inaclosed system an end of with the boiler should be connected to the blow off pipe in accordance with specifications Use specified blow off pipe to connect with blow off receptacle All these procedures should be done in accordance with local codes The water gauge and water gauge glass blow off valve should be connected to the main blow off line 4 Return pipes must not be the line trap should be installed zz I N EE E LL Safety Cnt ols eet Valve 0 l i Op JA LL Return Veni Water Column _ Sight Sight Gas Fired in dass Wate au Steam Boiler a Outlet _ Supply Off Check To Drain Valve Valves ge tan Electric Shut Check Off Control Vale Valve Thermometer p Blowdown Panel rg M To boiler Valve H Hd Hi i hr Feedwater Ae am Cold Water A A ak eg gi 77 Aquastat P Fast Opening Valve Joint Blow off Pipe B B 13 Description Instruction Boiler Installation The Steam Supply Pipe the Steam steam supply line from the top right ien side of the boiler auge The Steam Sa
38. ectrode jim Burner Plate 7 d Burner viewing Port Secondary Air adjustment Blast tube Air Deflector Top Plate NOTE The scanner is located on the outside edge of the burner top plate for 20 150 HP e Adjustments to establish a good signal may include the following items d For the RM7800 series use a 1 Primary and secondary air keyboard display module or adjustments voltmeter the flame safeguard will require a 1 25VDC signal to pull in the main flame Then a maximum signal should be obtained on main flame 5 0 VDC 2 Increase the pilot gas through the pilot gas regulator 31 Checking the Stainless Steel Combustion Ring for Fulton Gas Fired Steam Boilers a The stainless steel combustion ring in Fulton gas fired boilers are designed to bring quick and effective flame transfer to the flame wall The ring should fit securely and against the furnace wall for best results b The ring should be inspected for distortion in the event of poor combustion in the event of poor combustion which could result in flame failures Stainless Steel Ring Furnace Replacement Refractory Procedure a Remove the burner plate and top plate assembly up and out of the scroll assembly b Remove the stainless steel combustion ring from the furnace c Remove the clean out plugs from the bottom sides of the boiler 4 15 HP boilers have one clean out plug located at the panel box 20 60 HP boilers have o
39. eeded Replace pump with multistage centrifugal good for 121deg C 2 Impeller adjustment Check for impeller wear and adjust per component information in instruction manual 3 Back pressure on pump The pump needs to be repaired 4 Plugged Feed water Check and clean Nipple Water pump will not come on 1 Scale on probes Clean and replace at times 2 Bad Pump Contactor Check to see if contactor is being powered Check to see if contactor coil is pulling in or if the motor turns while pump does not run replace if necessary 3 Bad Pump Motor Check the incoming power to the pump to be sure it is receiving power If power is present but motor does not run replace it Boiler Flooding Maintenance Continued Boiler Flooding 4 Vacuum created with As the boiler cools off it pulls water from the system boiler off piping To prevent this add a 1 4 6mm check valve on the steam gauge assembly piping which closes under pressure and opens under vacuum boiler shuts down after it is to be closed Clean or replace Oil flames coming out 1 Bad draft condition Check draft with a gauge Draft should be a 0 02 to around the oil pump housing 0 04 W C with burner off or 0 04 to 0 06 when on shut down operating 2 Venting of room Check to see that doors to boiler room are closed to prevent air from being pulled out of the boiler area Make sure proper openings are available as described in the manual 46
40. fety Valve 1 Before installing be sure that Open i Ball Valve Closed fq all pipes and connections have been blown clean Pipe sealing dope is used on external threads only Be sure inlet of valve is free of any foreign material to avoid leakage of safety valve Inspection Test Valve Shown Open Steam 2 Do not use a pipe wrench When making installation use proper type and size wrench Steam Outlet 3 The valve should be installed in a vertical upright position in the connection provided on the top left side of the boiler Under no circumstances should there be a shut off valve or restriction of any kind between the safety valve and the connection provided Safety Valve Outlet 4 Do not cap or plug drain hole in the side of valve body 5 Since the purpose of this safety valve is to protect against an overpressure situation it will loudly discharge hot steam in doing so Therefore it is recommended that a discharge pipe be securely installed and run to a safe point disposal 6 When a discharge pipe is used it must be of a pipe size equal to or greater than that of the valve outlet Use pipe with a zz oo Lk To High Limit Pressure Control Operating Pressure Control sufficient strength extra strong or double extra strong discharge pipe or connections and it should be short and straight as far as possible to reduce the pressure on safety valve It must have an a
41. firing rate Both Equipped with Modulation pressure controls should have the same setting a Modulation is available as an option 1 NEMA 4 units will use a digital pressure on Fulton gas fired steam boilers for 30 Controller with transducer as the operating pressure control which 150 HP units only sends a 4 20 mA signal to the modulation motor to control firing rate b Boilers equipped with modulation will have the linkage rod disconnected between the modulation motor and the gas butterfly valve for shipment Modulating Gas Fired Burner ES EEE EHE EE c Mount the gas train on the pipe nipple of the burner plate with the gas train inlet directly facing over the panel box Reconnect the linkage from the butterfly valve to the modulation motor d The end of the linkage arm that attaches to the butterfly valve will have a notch on both sides of it where the swivel collar should be centered This setting was based on factory test fire conditions e Combustion analysis should be done at the installation to make any changes to insure proper combustion characteristics f The modulating burner will have a modulation lock switch in the panel box to enable you to lock the firing sequence anywhere along the firing rate from low to high Modulation Hold Lock Switch g Depending on the combustion Night Heating Pressure Control Optional characteristics it may be necessary to Proportioning Pressure Control adjust both
42. g Steam Pressure Control located in the control panel box and connected to the steam pressure gauge assembly by means of a copper tube The pressure control regulates the on off cycle of the burner shutting the burner off when maximum pressure is reached and switched on when the steam pressure falls below a predetermined level e Sight Glass Isolation Valves The brass sight glass isolation valves are equipped with an internal ball check In the event that a sight glass should break the ball will seat preventing the discharge of steam and water The brass valve stem must be opened fully to enable this feature If the valve is in any other position than full open the ball will not seat For added safety all Fulton boilers are equipped with gauge glass protectors Operation f High Limit Pressure Control located in the control panel box and connected to the steam pressure gauge assembly by means of a copper tube The pressure is usually set 10 15PSI about0 703 1 054kg cm2 above the operating pressure but below the maximum pressure of the pressure relief valve If the pressure exceeds the high limit pressure control setting the boiler will automatically shut off The high limit pressure control must be manually reset depressing the plunger located on top of the control The reset type controller is optional g Air Pressure Switch mounted on the burner scroll this switch is operated by the pressu
43. have read any followed all previous safety information Consult with local authorities where approval for start up is required b This switch should be turned off only when repairs or adjustments should be made In general ensure that the boiler area is in conformance with established boiler room NOTE The pump will continue to operate until the water requirements Review local codes 4 Open the water feed valve on the reaches the correct level in the boiler This level is approximately the center of the water gauge glass Carry out the following boiler procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down 7 Activate the boiler power on switch located on the side of the panel box 8 With the unit full of water the low water safety relay s willbe in a lock out mode Press the low water safety relay manual reset button located on the side of the control panel box 1 Close the blow off valve 5 Open valve on makeup water line to return system is used 6 Place feed water pump fused switch the on position 3 Open main steam stop valve at NOTE the top of boiler a The fused disconnect switch that controls the feed water should be kept in the on position at all times during the boiler operation as 26 Operation Oil Burner Set Up a Open the oil line shut off valves ff Y b Switch on the main power
44. he main gas valve giving a main flame e Fulton 4 30 HP natural gas fired boilers can be equipped with flame rods or UV scanners f All Fulton propane or butane boilers and more than 40HP Fulton natural gas boilers are standard furnished with UV Scanners g If the installation is new or the burner has been disassembled the burner may not fire at the first attempt due to air which must be purged from the gas lines This will result in the burner flame programmer going to lockout Repeat the procedure for starting the burner h The main gas valve will remain open as long as there is a demand for heat and the flame is carrying a sufficient signal to the flame programmer i If the flame is not established at the start the safety switch in the flame programmer control will open the contacts and shut off the burner j Push the reset button on the control to reset If trouble persists it may be necessary to check the flame rod setting or the UV scanner See Maintenance Section 4 for procedure to check flame rod setting or UV Scanner Operation BB ion civi Fulton PRESSURETROL woran m nenn VI nen 15 60HP Fuel Oil Gas MEC230 series Control panel 15 60HP Fuel panel 80 100HP Left 130 150 Right Fuel Oil Siemens series Control panel 28 Operation addition to the standard operating pressure control that will send a Gas Burner Set Up For Boilers 0 135 ohm signal to the modulation motor to adjust the
45. he source of the oil is determined and corrective steps taken Silica Silica in boiler deposits Description Instruction is usually combined with other constituents Silicates form a number of different scale complexes with calcium magnesium aluminum sodium and iron Since there is at present no effective dispersant for silicate deposits the scale problem can be alleviated by maintaining close control of calcium aluminum and iron as well as silica Iron oxides Iron in any of its oxide or complex forms is undesirable in boiler water It is very difficult to disperse so that it can be removed the bottom blow off lines Iron in its various forms can originate in the raw water makeup condensate return water or form directly in the boiler as a result of corrosion Most iron oxide originates outside the boiler It does not concentrate in the boiler and it tends to collect in stagnant areas If a boiler is using raw water makeup iron is almost certain to be a major component of developing scale Water Hardness Water hardness is the measure of calcium and magnesium content as calcium carbonate equivalents Water hardness is a primary source of scale in boiler equipment Feed water Feedwater is the combination of fresh makeup and returning condensate that is pumped to the boiler Condensate Condensate is condensed steam that is normally low in dissolved solids Hence it does not contribute to the disso
46. hould be 3 1 2 W C plus fan pressure at the elbow to the burner and 7 to 11 W C at the head of the train 3 Ignition Electrode Check electrodes for carbon build up and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 4 Primary Air Adjustment Check air adjustment Air may be blowing flame away from flame sensor 5 Oil Valve Check voltage between oil valve natural at terminal block to be sure oil valve is getting power 6 Oil pump Check for clogged strainer or filter Remove and clean Check for slipping or broken coupling Ti 42 Maintenance Continued Flame Failure 6 Oil pump replace Check for frozen pump shaft Replace 7 Flame Rod Adjustment Check flame for carbon buildup and clean if or UV Scanner necessary Check flame rod adjustment via a display module Flame signal should be 5VDC Check for cracks in porcelain If found replace Check for dirt on flame scanner and clean Check for proper location of detector Burner Cut off 1 Oil Supply Check oil level in supply tank to be sure it is not below intake line Fill tank with oil Check for clogged nozzle Clean or replace Check oil filter and replace if necessary 2 Gas Supply Check to be sure main gas cock is closed Check coil in gas valve with OHM meter Replace if faulty Check gas regulator setting and readjust as necessary Check inlet gas pressure and increase or decrease
47. l engage The main flame should be adjusted to an acceptable flame signal to ensure continued performance A poor signal will going off safety b A single flame rod is used on 4 15HP Fulton Boilers and two flame rods on 20 and 30HP If the boiler has two flame rods adjust the flame rod in the burner plate first with the outside one disconnected After a good pilot signal is established on the inside flame rod then the outside flame rod can be hooked up and the signal adjusted for X proper responses C If a signal is erratic after adjusting the flame the main and secondary air supplies may need adjusting If a flame rod is cracked or broken the porcelain will have to be replaced to get a proper signal Flame Scanner Adjustments for Fulton Gas Oil Fired Steam Boilers a Flame scanner adjustments are made with the detectors installed and the burner running It is essential to obtain optimum flame signal detection for safe and continual operation of the control relay b If a scanner is inoperable it may prove the detector is working and only an adjustment to the pilot flame is needed to improve the signal c If the scanner is found to be defective replace Maintenance Air Gate Cad Cell 4 15HP Burner Plate Secondary Air Adjustment Port Top Plate Observation Port Air Deflector Blast Tube CadCell 4 15HP scanner 20 1 50H Primary Gate Oil Inlet g ignition El
48. l fired boilers Refer to left hand column of the chart to locate the problem Determine which cause listed in the center column That presents the problem by performing the corrective action as listed in the right column titled REMEDY Troubleshooting for steam boilers Ignition Failure 1 Power Supply check fuse or circuit breaker Reset or replace as necessary 2 Ignition Electrodes Check electrodes for carbon built up and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain If found replace 3 Transformer Check voltage between transformer leads at terminal block to be sure transformer is being powered 4 Cad Cell Check for ignition interference 5 Flame Check voltage between pilot terminal neutral and Safeguard Burner Control ignition terminal neutral Check must be made before control locks out on safety If no power replace control 6 Oil Nozzle Clogging Check oil nozzles and clean or replace as necessary 7 Gas Valve Sticking Check for dirt in valve or orifice and clean if pilot necessary Check for faulty actuator or vaslve and replace if necessary Flame Failure 1 Oil Supply Check oil level in supply tank to be sure it is not below intake line Fill tank with oil Check for clogged nozzle Clean or replace Check oil filter and replace if necessary 2 Gas Supply Check for gas pressure and for intermittent supply problems Gas pressure for natural gas s
49. lower the amount of dissolved d Chlorides can be controlled by increasing the number of blow down per day from one to four e The Fulton warranty does not cover damage or failure that can be attributed to corrosion scale or dirt accumulations Oxygen is a corrosive See the Warranty Section of this manual for full details Recommended Water consulted prior to the installation of the boiler oxygen in the boiler feed Treatment water is the sparge tube option This option injects live steam into the feed water to increase the water temperature to 82 degrees C which remove oxygen from the water The boiler should be in accordance with GB1576 2001 Industrial Boiler Water Quality Following are detail data for feed water treatment outside the boiler b The purpose of this treatment should be to provide quality feed water to the boiler such that corrosion and deposition in the boiler will be minimized Mey mmo o lt 2 0 3 With Super heater mg L Without Super heater SO3 mg L Dissolved Solids Relative Alkalinity Free NaOH Dissolved Solids Oil mg L ron mgl Note Oxygen had better be removed to make a dissolubility of equal to or less than 0 1mg L If there is partial corrosion because not removal of oxygen the action must be done for removing o mot ooo 17 Glossary of Water Supply Dissolved Oxygen Oxygen that is dissolved in the feed water will cause the steel in the boiler an
50. lved solid content of the feed water In addition condensate is very expensive to waste It s been chemically treated heated pumped converted to steam and condensed This costs money and when condensate is returned to the boiler money is saved Electrical Requirements a Connect wiring as shown in the wiring diagram which is furnished inside the electrical control panel box b Be sure to install a separate fused disconnect for each The disconnect should be installed in compliance with all local codes c Connections for an optional audible alarm are provided in the control panel and are clearly indicated on the diagram Fresh Air Supply for Boiler Room a It is most important to provide free access of air to the boiler 6 4cm is needed for every 756 Kcal b Proper ventilation of the boiler room is essential for good combustion Install two fresh air openings one at a low level of 610mm from floor and one at a higher level on the boiler room See the picture This will provide a flow of fresh air intake into from the bottom hole and exhaust the hot air from the top hole c The following openings are recommended for each size boiler 19 Description Instructions Make UP Air Openings 100 130 150 BT 1 5 0 09 0 09 14 Of Of 46 7 5 75 069 Be sure total BHP air opening size For instance if you have three 10 BHP boilers it is a total BHP of 30
51. mp Coupling Fan to Oil Pump Coupling Fan to Oil Pump Coupling Fan to Oil Pump Burner Plate Oil Burner Plate Oil Burner Plate Oil Burner Plate Air Gate U K Air Gate U K Air Gate Parts HP 6 15 20 30 50 60 80 100 HP 10 15 30 20 40 50 60 80 100 130 HP 4 30 40 100 HP 4 10 4 10 15 100 HP 4 15 20 30 40 100 40 100 4 30 HP 6 20 30 100 HP 4 15 20 100 50 Continued Item 16 17 18 19 20 Part No 2 20 021 2 30 149 5 20 021 2 12 014 2 20 003 2 20 004 Electrode Parts 11 Ignition Electrode Ignition Electrode Holder Ignition Electrode Holder Pyrex Plate Glass 1 Single Oil Nozzle Adaptor Double Oil Nozzle Adaptor Parts HP 4 100 4 20 30 100 4 100 30 100 51 Gas Burner and Ignition Assembly 7 15109 12 Parts 52 Gas Burner and Ignition Assembly Components Item 1 Part No 2 40 605 2 40 606 2 40 603 2 40 770 2 40 608 2 40 611 2 40 609 2 40 771 2 40 613 2 40 615 2 40 614 2 40 621 2 40 773 Burner Motor 1 3HP 115 230 60 1 1 3HP 230 460 60 3 1 3HP 110 220 50 1 1 3HP 380 50 3 3 4HP 115 230 60 1 3 4HP 230 460 60 3 3 4HP 110 220 50 1 1 5HP 380 50 3 1 5HP 115 230 60 1 1 5HP 230 460 60 3 1 5HP 110 220 50 1 3 0 HP 230 460 50 60 3 3 0HP 380 50 3 The correct part number is located on the burner motor Item 2 Item The correct part number is located on the back of the fan plate Item 4 Item Part No 2
52. mple provision for draining condensate at or near the valve outlet It must terminate freely to atmosphere and maintain normal atmosphere pressure no pressure difference with outside The Steam Pressure Gauge Assembly The gauge should be facing front towards the panel box and or operator of the boiler Except as noted each assembly or any of its component parts may be oriented other than shown to provide improved operating clearance and or view of gauge Before installing steam gauge on the siphon add a small amount of distillate to the gauge element for sealing This must be completed to prevent inaccurate pressure readings and or 14 premature failure of the gauge Install the steam gauge into the siphon on the water column The Blow off Valve There are three blow off valves on the boiler the main valve at the rear of the boiler the water gauge glass blow off valve and water lever blow off valve The boiler blow off valves supplied with the boiler should be connected to the blow off pipe in accordance with specifications Use specified blow off pipe to connect with blow off receptacle All these procedures should be done in accordance with local codes The feed Water Piping 1 Provisions must be made for adequate water supply and properly sized piping Piping must be done in compliance with all local codes The following chart may be used as a guideline for sizing Minimum Water Supply Piping Siz
53. n check steam traps and check to be sure return lines are not insulated Check return tank temp If it ids above 82 degree of C vapor locking of pump will occur Inspect check valves Clean and replace as needed Replace pump with multistage centrifugal good for 121deg C 7 Too much of a load Check total equipment horsepower required against horsepower of boiler being used Decrease amount of equipment being used at one time 1 Draft problem Check draft with a gauge Draft should be a 0 02 to 0 04 W C with burner off or 0 04 to 0 06 when Boiler Rumbles and Pulsates operating 2 Too much primary air Check primary air adjustment 3 Air or water in the oil Check tank and lines for water and air Boiler pushing water with the 1 steam traps Check traps Clean or replace as necessary steam 2 Too much boiler Dump return tank and flush system Have water compound tested by water treatment company Pump will not cur off 1 Dirty Probes Clean or replace as necessary 2 Relay failed Make sure relay is plugged in tightly If so replace water level relay 3 Ground connection Check for ground connection condition 1 Vapor locking of pump Allow system to cool down check steam traps and check to be sure return lines are not insulated Check return tank temp I f it ids above 82 degree of C vapor Pump runs but does not put water into boiler locking of pump will occur Inspect check valves Clean and replace as n
54. n on the feedwater treatment employed since the installation of the boiler Consult Fulton Boiler Works Inc for analysis of acceptable water conditions Feedwater treatment and proper daily blowdown procedures are very important in keeping your boiler heating surfaces free of scale formation pitting oxygen corrosion and foaming or bouncing water They will recommend the proper treatment required for prolonging boiler life A thorough boiler inspection should take place during the first three months of operation to assess the effectiveness of boiler water treatment techniques including analysis of potential oxygen pitting It is the owner s responsibility to assure safe operation of the boiler To avoid corrosion scale or dirt accumulations it is recommended that a daily blow down procedure be instituted The boiler power should be left on during daily blow down so that correct operation in the low water relay may be checked While blowing down the boiler the pressure will drop significantly While blowing boiler down with power on it is normal to hear the boiler feed pump come on The burner should not turn on If the burner does come on turn the boiler off and contact our factory immediately Corrosive acid and chlorine based chemicals in the atmosphere can be damaging to this boiler It is the owner s responsibility to have the boiler room periodically tested to assure these damaging chemicals are not present 1 Year 12 Month Standard Warra
55. n use the 1KW 220V constant voltage with high accuracy e Weare not in charge of the problems caused by that the feed water is not as the manual requires such as no soften water equipment e Please install fuel lines filter otherwise the user bear themselves It will be valid that this card must be written and sent back to Hang Zhou Fulton Thermal Equipment co Ltd after purchases 40days may be copies DUC TIN INDUSTRIES LIMITED COMPANY Head Office 6 16 Fourth Quater Tan Chanh Hiep Ward Dist 12 HCMC Rep Office 8 10 Nguyen Ba Tuyen Str Ward 12 Tan Binh Dist HCMC Tel 08 6297 3207 Fax 08 6297 3209 Hotline 0982 455 456 Email info Qductin com vn Website www ductin com vn Duc Tin Industries 63
56. nal Inspection h Crating inspection Instruction All units can be transported with forklift Under no circumstances should weight be allowed to bear on the jacket control panel or fan housing of any Fulton Boiler The customer should examine the boiler for any damage especially the refractory Rigging your boiler into position should be handled by a experienced in handling heavy equipment Section 1 2 Safety Warnings Cautions Notes Description Instructions Specifications amp Dimensions 4HP 150 HP Locating the Boiler The Fuel Oil Supply The Gas Supply Boiler Condensate Tank and Blow off Separator Piping Boiler Installation Water Supply Glossary of Water Treatment Electrical Requirements Fresh Air Supply for Boiler Room Conventional Venting Exhaust Side Wall Venting Combustion Air Intake Corrosion of Flue Pipe Installation Checkpoints Cleaning the Pressure Vessel Operation Starting the Boiler Oil Burner Set Up Gas Burner Set Up Primary Air Adjustment Secondary Air Adjustment Boiler Controls Maintenance Procedure for Cleaning Water Probes Flame Rod Adjustment Flame Scanner Adjustment Checking Stainless Steel Combustion Ring Furnace Refractory Replacement Procedure Recommend daily Maintenance Recommend Weekly Maintenance Hecommend Monthly Maintenance Recommend Semi Annual Maintenance Recommend Annual Maintenance Trouble shooting Parts Oil Burner and Ignition Assembly Comp
57. ne clean out plug located at the bottom of the boiler to the right side of the panel box 80 150 HP boilers have two clean out plugs located at the bottom of the boiler to the left and right sided of the panel box d Break off the top holding clips that were to keep the refractory in position during shipping The 4 50 HP boilers also have holding clips beneath the top refractory There is no need to cut the holding clips located beneath the top refractory as the refractory may be rotated to avoid these clips during installation of the lower refractory The 60 150 HP boilers have welded flats bars beneath the top refractory These bars will have to be cut to change the lower refractory and refitted as the top refractory is installed For the lower refractory you will also need to break off the top holding clips that were used to keep the refractory in position during shipment e Break up the top and or bottom refractories and remove the pieces from the through the clean out plugs NOTE If only the top refractory is to be changed the bottom refractory need not be broken f Round and bevel the outer edges of the new refractories g The bottom refractory has the largest hole while the top refractory has the smallest h Lower the bottom refractory Maintenance down the furnace with wire fastened around the refractory in three positions When the refractory is close to position it can be tipped by maneuvering the
58. nswer these questions and send back to us Is it the first time that you purchase boiler Yes No Will the boiler be instead the old one Yes No If Yes please indicate the instead one s type and factory If the instead one is Fulton boiler tell us why If the instead one is the other tell us why Do you think the price of Fulton boiler compared with the others is suitable JYes No Note Which ways do you know about Fulton boilers Your Fulton Boiler is standard high efficiency and economic 62 Warranty Guarantee Card of Fulton Boiler Which affect you the deepest among the character of Fulton boiler Design of vertical with no tube The operation is simple PV 3years warn y Maintenance easily Steel components of electric boiler efficiency Burner with special design of Fulton safety Talk about the impression to Fulton with simply words Do you still purchase Fulton boiler yes No Why Please tell us the reason Please read carefully the user manual from Fulton and operation and maintenance must be in accordance with this manual Note The inlet voltage of electric panel box must be kept at the ranges of 200V 10 otherwise the controller can be damaged and the constant voltage equipment is advised If the boiler draft and panel box both use 220V 1 use the 3KW 220V constant voltage with high accuracy If the draft use 380V 3 but panel box use 220V 1 the
59. nty A Fulton Boiler Works Inc will repair or replace any other part of this boiler of our manufacture which within twelve months of the date of shipment from factory is found to be defective in workmanship or material provided the equipment has been installed operated and maintained by the buyer in accordance with the operating instruction manual provided with the equipment and generally accepted approved practices and on the provision that the buyer gives proper notification in writing as soon as the defect take place and that he has properly filled out and returned his warranty card This warranty does not include labor charges of any kind Follow maintenance instructions as listed in the Instruction Book B But Fulton Boiler Works Inc does not provide any warranty for products manufactured by others C The electrical elements for Fulton boilers request the working voltage in the range of 220V 10 if the user can not ensure this request of voltage safety voltage regulator power must be fitted Otherwise the electrical elements damaging caused by voltage not as request is not in the range of warranty 60 Boiler Type Steam Oil Boiler No Company Address Linkman Purchase Date Address and Tel Direct Maintenance charger Oil and Gas Filter Files Card for Fulton Boiler Users Hot Water Gas Tel Postcard Distributor Water Treatment Equipment Yes Type No Yes Type No Voltage fit voltag
60. ogged nozzle Clean or replace Check oil filter and replace if necessary 2 Oil Nozzle Check for clogged nozzle Clean or replace 3 Oil valve Check if there is leakage 4 Oil Pump Check if the filter is blocked 5 Gas Supply Check gas pressure coming ito gas train If low contact gas company Should be 7 to 11 W C Check coil in gas valve with OHM meter Replace if bad Check gas regulator setting and readjust as necessary 6 Dirty Flue Check flue for dirt buildup clean the flue passages 7 Scale Built Up in Boiler Call water treatment professional and consult Fulton company 8 Pressure Control Disconnect all power to the controller Disconnect the wires from the controller Put an OHM meter between the switch terminals Lower the set point of the controller Switch should make Raise the set point and recheck with OHM meter Switch should break If the controller operates improperly replace it Boiler is surging 1 Steam traps blowing Check traps to see if they are clean or replace as through necessary 44 Maintenance Continued Boiler is surging 2 Perc cleaning solvent in Clean boiler with washing soda per instruction 3 Scale build up or lime Call water treatment professional and consult Fulton deposits company system water treatment tested by water treatment company 5 Too much water Have water tested by water treatment company 6 Vapor locking of pump Allow system to cool dow
61. oint Operation Fi ie E i L f i E Mig ht Heating Pressure Control Optional Low firePressure Control Panel Box for Boilers equiped with high low off firing 30 Warring Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be disconnected Primary Air Adjustment for Fulton Gas Fired Steam Boilers a The primary air adjustment or main air control is located at the fan housing face This control is used to supply the burner with excess air needed to facilitate good combustion Too much or too little air will result in poor combustion It is important to make sure the lowest level of excess oxygen is present while still maintaining a high level of carbon dioxide and negligible carbon monoxide Using a COzor Ostester it is possible to determine the percent of excess air in the combustion mixture b On a No 2 oil fired boiler the excess oxygen should be 4 percent with 11 percent carbon dioxide A smoke test is the best means to check for combustibles in the flue gases A smoke test of 0 2 is an acceptable level It is best to measure the flue gas with the stack in excess of 216 degree of C To increase the oxygen in the burner open the air adjustment to the right To close or reduce the secondary air move it to the left e Secondary Air Adjustment for 4 20HP Operation UEFONEBOTER
62. onents Gas Burner and Ignition Assembly Components Sketch of Layout for Boiler Room Warranty Files Card for Fulton Boiler Users Guarantee Card of Fulton Boiler Contents Safety Warnings Cautions amp Notes Safety Warnings Cautions amp Notes The following WARNINGS CAUTIONS and NOTES appear in various chapters of this manual They are repeated on these safety summary pages as an example and for emphasis WARNINGS must be observed to prevent serious injury or death to personnel CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating efficiency NOTES must be observed to keep boiler being operated with high efficiency It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to fully understand the WARNINGS CAUTIONS and NOTES by which hazards are to be reduced or eliminated Personnel must become thoroughly familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment CAUTION Some matters used for leak testing are corrosive to certain types of metals Rinse all piping thoroughly with clean water after leak check has been completed NOTE Where a return tank is to be fitted this should 1 Be vented and 2 Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank temperature oafety Warnings 3 Vent pipe should not be do
63. ortant that the feed water and the boiler water are mixed thoroughly and as quickly as possible so that boiler water sodium sulfite may consume feed water oxygen before the latter can cause damage to the boiler oulfite as a treatment represents a second line of defense against oxygen corrosion A vigorous maintenance program to safe guard against oxygen leakage into the pre boiler system should be followed Suspended Solids Suspended solids are the undissolved matter in water including dirt silt vegetation and any other insoluble organic matter Normally suspended solids are expressed in terms of turbidity The presence of suspended solids in cooling water can increase impingement type corrosion Suspended solids may also deposit in low velocity areas and create differential aeration cells Pitting can result The most common cause of high suspended solids is high hardness feed water Of the agents which cause foaming suspended solids probably have the least effect Reasons for the increased hardness or other suspended solids should be determined In line filters or various types of pretreatment can be used to lower the suspended solids level Various polymers assist in holding solids in suspension Alkalinity Alkalinity is the capacity of a water to neutralize acids Common water alkalinities consist of bicarbonate carbonates hydroxide phosphate and silicate These alkalinities especially bicarbonates an
64. oth glass packing nuts then tighten 1 2 turn more by wrench Tighten only enough to prevent leakage DO NOT OVER TIGHTEN If any leakage should occur tighten slightly a quarter turn at a time checking for leakage after each turn 11 Install the protective guard Gauge glass valves utilize automatic ball checks to help prevent injury in case of glass breakage WARINING Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and or property damage Top Gauge i Fitting Gauge Glass Guard Rod Glass Packing Nut Glass Packing Bottom Gauge Fitting Drain Valve A Friction Washer ar 3 ot fal re 16 Water supply a Feed water contains solids and dissolved gases These may promote incrustation of scale corrosion etc To prevent this feed water must be studied individually and treated accordingly by reputable professionals specializing in this field It is strongly recommended that a competent water treatment specialist be Description Instruction Dissolved oxygen high chloride levels and low PH can all be major causes of corrosion Untreated hardness is the major cause of deposits Poor quality feed water requires increased blow off and increased chemical treatment costs to prevent boiler corrosion and scaling c One way to
65. r These pieces of metal act as the formed combustion ring effect during manufacture This is a normal condition and does not affect the efficiency and the life of the boiler in any way Description Instruction Description Instruction Transformer scroll Burner Mortor Magnetic Gas Wale O P C perating Pressure Control Gas Train H P C High Pressure Control A WAPE 4 TOH P C Assembly E Secondary Air Damper Top Flate Assembly Steam Gauge Assembly Flue Plate Cover Gauge Glass Valve Flue Rope Gasket _ NE Flue Blanket j _ Water Gauge Glass and Lifting Hooks Protector Stainless Vater Column steel Ring Flue Outlet Gauge Glass Valve Top Refractory Control Box High Density Insulations Feed Water Inlet Outside Jacket Bottom Refractory Handhole Blowdown Outlet Castable Refractory Insulation Boiler Runners __ Description Instruction Specifications StandardModelsrBasics 4 6 w is 20 3e 4 so oo so wo 130 150 Boiler HP a 6 1 1 20 30 40 so oo so 10 130 150 Ratings sea level to 914m Outputfsteam bir 138 207 sas sis 690 1035 1380 1725 2070 2760 saso sasa 5175 Kar 2348 Approximate oil gas Consumption at Rated Capacity Light oil kg h 14 71 1891 29 07 3841 48 80 58 14 76 10 91 31 12175 14055 Town gas m h 12 06 18 09 30 14 47 06
66. re of air entering the burner through the throat of the scroll Absence of air or insufficient pressure will prevent the switch completing the circuit thus preventing the burner from operating preventing the burner from operating 32 CAUTION When stopping the boiler for any extensive repairs shut off main disconnect switches on both the boiler side as well as the feed water side NOTE To ensure that your Fulton Steam Boiler is kept operating Operation safety and efficiently follow the maintenance procedures set forth in section 4 of this manual 33 Maintenance 34 Maintenance Transformer Scroll Burner Martar E 3 LLLI lr if ri f j A Magnetic Gas valve O P C Operating Pressure Control Gas Train H P C High Pressure Control E ar ur Ope Ta HPLC L Assembly Secondary Air Damper Top Plate Assembly d Steam Gauge Assembly Flue Plate Cover Gauge Glass Valve Flue Rope Gasket AN Flue Blanket m Water Gauge Glass and Lifting Hooks Protector stainless Water Column steel Ring Flue Outlet Gauge Glass Valve Tap Refractory Control Box High Density Insulations Feed Vater Inlet Outside Jacket Bottom Refractory Handhole Blowdown Outlet Castable Refractory Insulation Boiler Runners ____ 35 NOTE To ensure the continued safety efficiency of the boiler the schedule
67. s held together with fasteners are free of nonconductive coatings and are protected against mating surface corrosion 2000 W maximum connected load to EC7830A Assembly Use section that more than 2 5mm soft wires to connect The power must insure the rated requires and fit voltage regulator power otherwise not in warranty range Total load current excluding Burner motor and firing transformer outputs cannot exceed 5A 25A inrush 56 Water Column Parts Part No 5 20 022 5 20 048 Part No 2 12 017 2 12 065 Part No 2 30 149 2 30 155 2 12 020 2 12 019 2 35 514 2 30 330 2 12 022 2 12 204 Part No 2 20 010 2 20 011 2 20 012 2 20 017 2 21 012 2 21 013 2 30 398 Water Column Bottle Casting 1 Water Column Bottle Casting Water Column Bottle Casting Water Gauge Glass 2 9 1 4 Water Gauge Glass Coming 8 5 8 Extra Heavy Gauge Glass Water Gauge Glass Trim Water Gauge Glass Valves w Ball Checks 3 Conbraco 250 GGValve w Ball Check Brass Water Gauge Glass Gasket 4 Rubber Water Gauge Glass Gasket 5 Brass Packing Nut for Gauge Glass Valve 6 Gauge Glass Protector Rods 7 Lucite Gauge Glass Guard 9 1 4 Glass 8 Lucite Gauge Glass Guard 8 5 8 Glass 8 Water Level Probes Pump Off Probe 7 1 4 9 Pump On Probe 9 1 4 10 Low Water Probe in Water Column 11 1 4 11 Low Water Probe in Boiler 17 1 8 12 Probe Cover 13 Probe Basket 14 1 4 Ball Valve for Water Column 15 BHP 4 30 5
68. t the oil supply lines from the tank to the burner are of proper size Vacuum should not exceed 10 of mercury at the oil pump inlet b All Fulton oil burners are of the two pass design system requiring a return line and supply line The oil pump is factory set at 230 psi 216 Kg cm Do not change this setting without allowance of Fulton Boiler C A stop valve a check valve and an oil filter must be installed in the oil supply line d When one oil line is feeding two burners a check valve must be installed in each unit e Make sure there are no loose fittings Loose fittings in the fuel oil line will allow air to enter into the fuel line and cause improper firing The Gas Supply a Gas piping should be installed in accordance with National Fuel Gas Description Instruction Code and any other local codes which may apply b Install a dirt trap ahead of all of the gas valves c The pipe and the fittings used must be new and free of dirt or other deposits d The piping must be of the proper size to ensure adequate gas supply to the gas head assembly Consult your gas company for specific recommendations e For natural gas a pressure of 7 to 11 178mm to 279mm of water column pressure at the gas train is required with burner firing Do not exceed 13 of water column f For propane or butane gas the pressure required is 11 279mm of water column pressure Again do not exceed 13 of water column
69. t use the glass if it contains any scratches chips or any other visible signs of damage 3 Do not subject the gauge glass to bending or torsion stresses 4 Apply PTEE tape or emulsion to pipe threads Install top gauge fitting fitting without a drain valve into the uppermost tapping Wrench tight the fitting until it is snug and the glass outlet is pointing at five o clock 5 Install the bottom gauge fitting fitting with a drain valve until itis snug and the glass outlet is pointing directly upward Verify top and bottom fittings are threaded into the tapings the same number of turns distance A distance B Description Instruction 6 Remove glass packing nut friction washer and glass packing from the fittings and place them in the same order on both ends of the gauge glass Push both packing about an inch up the gauge glass 7 Gently insert one end of the glass into the gauge fitting Keeping the glass inside the top fitting gently rotate the top gauge fitting clockwise until vertically aligned with the bottom gauge fitting then inset glass into bottom fitting until glass bottoms out on the shoulder inside the bottom fitting 8 Carefully raise glass about 1 16 1 6mm and side lower glass packing down until the glass packing contacts the lower gauge fitting DO NOT allow the glass to remain in contact with any metal 9 Carefully slide upper glass packing up as far as possible 10 Hand tighten b
70. to the burner TEE Mike Depress the manual reset button on the panel box eww slowwe c To start the burner turn on the switch located on the panel box The blower motor will now start to deliver the air into the furnace After the blower starts about 7 to 30 seconds the magnetic oil valve is energized allowing the oil pump to deliver fuel to the furnace where it is ignited d On Fulton 4 10 HP oil fired boilers the burner control sights the fire from a cadmium sulfide photocell located on top of the burner If it does not detect the flame in approximately 15 seconds it will go out on safety lockout and shut down the burner e On Fulton 15 150 HP oil fired boilers the flame safeguard control sights the fire from an ultraviolet scanner located on top of the burner There will be a first stage pilot before the main oil valve is energized After flame is proven the main oil valve will come on If flame is not proven it goes into safety shut down Note 4 20 BHP have only one stage 30 150 i 1 BHP have two fh 2o en neo f Reset by depressing the button on the flame safeguard control If boiler does not respond after 3 attempts contact your authorized Fulton Representative g The main air control shutter is adjacent to the oil pump and should be adjusted so as to give a clean burning fire without excess air being delivered to the burner h The secondary air control is an L type handle located on the top of
71. wnsized This may cause pressure build up in the condensate tank 4 Return pipes must not be insulated This can cause overheating the return system causing a vapor lock in the pump 5 See Return System Instruction Manual for detailed instructions NOTE Care should be taken to ensure that the blow off receptacle used meets the regulations covering such vessels If in doubt consult Fulton for a advice NOTE Only properly trained personnel should install and maintain water gauge glass and connections Wear safety glasses during installation Before installing make sure all parts are free of chips and debris NOTE Keep gauge glass in original packaging until ready to install WARNING Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and or property damage NOTE After installation is completed and prior to operation the pressure vessel should cleaned CAUTION Do not store halogenated hydrocarbons near or in the boiler room Cautions amp Notes NOTE a The fused disconnect switch that controls the feed water pump should be kept in the on position at all times during the boiler operation as well as during the non operating period of the boiler b This switch should be turned off only when repairs or adjustments should be made NOTE The pump will continue to operate until the water reaches th

Instruction, Operation, and Maintenance Manual Fulton Oil Fired

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