INSTALLATION AND OPERATION MANUAL Vertical Coil Design Thermal Fluid Heaters Models FT-C and FT-S Serial / National Board Number Model Fulton Order Sold To Job Name Date FTCS-IOM-2013-1114
INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE PARTS & WARRANTY Questions? Call (315) 298-5121, or visit us online at www.fulton.
INTRODUCTION FTCS-IOM-2013-1114 SECTION 1 Overview Warnings & Cautions Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers: WARNINGS and CAUTIONS appear in various chapters of this manual. It is critical that all personnel read and adhere to all information contained in WARNINGS and CAUTIONS. Material inspections WARNINGS must be observed to prevent serious injury or death to personnel.
TABLE OF CONTENTS FTCS-IOM-2013-1114 Introduction 1-1 Overview .............................................................................................................. 1-2 Warnings & Cautions............................................................................................ 1-2 Disclaimers and Local Codes ................................................................................ 1-2 Installation 2-1 Placement & Rigging .............................................................
TABLE OF CONTENTS FTCS-IOM-2013-1114 LIQUID LEVEL SWITCH ................................................................................................................4-6 STACK LIMIT .................................................................................................................................4-6 DIFFERENTIAL PRESSURE SWITCH .............................................................................................4-7 LOW INLET PRESSURE SWITCH ........................................
INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE PARTS & WARRANTY Questions? Call (315) 298-5121, or visit us online at www.fulton.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Unless otherwise noted, this heater is certified for indoor installation only. A competent rigger experienced in handling heavy equipment should handle rigging your equipment into position. The equipment must be installed on a non-combustible surface.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 Clearances & Serviceability Adhere to the following for equipment clearances and serviceability: 1. Ensure appropriate front, back, sides and top clearances are met. This will allow access around the equipment to facilitate maintenance and a safe work environment, and ensure technicians will commission the unit. Technicians will not commence commissioning if hazardous conditions exist. 2.
INSTALLATION FTCS-IOM-2013-1114 SECTION 2 Environment, Ventilation and Combustion Air Requirements Ventilation must be sufficient to maintain a building temperature of 120°F (49°C) or less. Consistent proper ventilation of the equipment room is essential for good combustion. NOTE: When calculating ventilation requirements, heat losses from the Fulton equipment (and other equipment) should be considered. A Adhere to the following to meet ventilation and combustion air requirements: 1.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 TABLE 1 - SPECIFICATIONS - COIL DESIGN THERMAL FLUID HEATER Model FT-C 0080 0120 0160 0240 0320 0400 0600 0800 1000 1200 1400 800 200 1,200 300 1,600 400 2,400 600 3,200 800 4,000 1,000 6,000 1,500 8,000 2,000 10,000 2,500 12,000 3,000 14,000 3,500 GAL LITERS 10 38 21 80 19 72 31 116 68 258 76 288 132 498 171 648 290 1,097 383 1,448 460 1,741 GPM M3/HR 50 11.4 75 17 100 22.7 150 34 250 56.8 250 56.8 375 85.2 500 113.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. A qualified installer, service agency or the gas supplier must perform installation and service on the fuel delivery system. Do not use matches, candles, flame or other sources of ignition to check for gas leaks.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 combustion or nuisance failures. matter to be in the combustion air supply (e.g., as a result of construction and maintenance activities).
INSTALLATION FTCS-IOM-2013-1114 Butterfly Valve Gas Safety Shutoff Valve SECTION 2 HI / LOW Gas Pressure Switch Main Gas Regulator Manual Gas Valve 2” N.P.T. Gas Connection Manual Gas Valve Pilot Gas Valve Pilot Gas Regulator FIGURE 3 - TYPICAL GAS-FIRED MODULATED CSD-1 FUEL TRAIN Pilot Gas Valves 2” N.P.T.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 8. During any pressure testing of the system at pressures in excess of 1/2 psig (14 inch W.C.)., disconnect the heater at the heater manual shutoff valve (located at the end of the supplied gas train) from the gas supply piping system. with the model of heater. The requirements for natural gas-fired coil design models are as follows: 9. Ensure the supply pressure is regulated by a nonstacking, tight, shut-off regulator. 10.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. The vent line connection on the gas pressure regulator must be piped to outdoor air by the installer in accordance with National Fuel Gas Code, ANSI Z223-1-1991 or latest addenda. In Canada, gas installations must be in accordance with the current CAN/CGA B149.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 Electrical Supply Adhere to the following for electrical supply installation: 1. Install wiring and ground in equipment in accordance with authority having jurisdiction or in absence of such requirements the National Electrical Code, ANSI/NFPA 70. 2. Provide a wall-mounted, fused disconnect sized for the unit. This must be fitted by the client/contractor if disconnect is not supplied on the panel. 3.
INSTALLATION ! FTCS-IOM-2013-1114 frequency. WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. For 3-phase motors, the line to line full load voltage must be balanced within 1% of the rated motor voltage. If the motor is rated 208-230V, the voltage deviations must be calculated from 230V.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 developed to give thermal stability over a very wide range of temperature. A wide variety of thermal fluids have been used successfully in Fulton Thermal Fluid Heater systems, however, your final selection should be made in conjunction with recommendations from Fulton Thermal Corporation or the fluid manufacturer. Consider the following for selection: 1.
INSTALLATION ! Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. CAUTION Proper selection of thermal fluid is critical to system performance. If excessive amounts of thermal fluid are vented from the system, additional thermal fluid may be required in the system. Contact Fulton for further information.
SECTION 2 also result in thermal fluid breakdown. Fulton heaters are equipped with a temperature limit switch (located on the front of the panel box) to prevent this from occurring. INSTALLATION FTCS-IOM-2013-1114 A high temperature limit switch is an over temperature safety device. If the high temperature limit shuts down the unit, the manual reset button on the limit switch must be pressed. The reset button on the flame programmer must also be pressed to reset the unit before it can be restarted.
INSTALLATION FTCS-IOM-2013-1114 Adhere to the following for piping installation (see Figure 8): 1. Ensure the arrangement of the piping and its appurtenances takes into consideration the location of other structures and equipment adjacent to the piping, which may result in freezing interference and/or damage as a result of expansion, contraction, vibration, or other movements. 2. Consider the appropriate location and orientation of valves necessary for safe operation and isolation of the piping.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 6. If an isolating valve is completely closed, the pressure in the system will rise to the deadhead pressure of the pump. Suitably sized pipe will enable the system to withstand the total head generated by the circulating pump, should this occur. In applications where it is desirable to design to pressures lower than 100 psig, an alternative safeguard is to install appropriately sized safety valves. 7.
INSTALLATION ! FTCS-IOM-2013-1114 new tools should be used. Threaded connections larger than 1” are not to be used. It is recommended that GR5 or higher tensile steel bolts be used for all flanged joints. WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Non-Fulton product information is for reference purposes only.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 TABLE 6 - RECOMMENDED GASKET LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 150# GASKETS SAE GRADE 5 BOLTS OR EQUAL Nominal Flange Size (inches) Number of Bolts Diameter of Bolts (inches) Preferred Torque Req.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 Insulation After the appropriate system tests have been satisfactorily completed (see Testing section of this manual), all hot pipework and vessels must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury. Adhere to the following for insulation installation: 1. For inspection and maintenance purposes, leave pumps, flanges, valves and fittings uninsulated but suitably shielded for safety.
INSTALLATION FTCS-IOM-2013-1114 Thermal Fluid Circulating Pump Installing the pump in accordance with the manufacturer’s specifications and these instructions will prolong the life of the pump and contribute significantly to the successful operation of your Fulton heater system. The pump manufacturer’s installation and operation instructions can be obtained from the manufacturer. Adhere to the following for pump installation (see Figure 9): 1. Locate pump adjacent to the heater.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 The coupling alignment of the pump and driver must be carefully checked for angular and axial alignment. Check pump manufacturers instructions for these specifications. The use of a dial indicator to check the axial and angular alignment is recommended. An air cooled pump does not have an oiler. This type of pump has a sleeve bearing which is, like the seals, lubricated by thermal fluid.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. FTCS-IOM-2013-1114 SECTION 2 Combination Deaerator/Thermal Buffer/Expansion Tank Fulton Thermal’s efficient design combines the operation of the expansion, deaerator, and thermal buffer tanks.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 C 1/2C 3 VENT (76) N2 REGULATOR K (TYP.) 1/2 (13) 2 (50.8) R F P SAFETY RELIEF VALVE CONN. A LIQUID LEVEL SWITCH COUPLING M DEAERATOR THERMAL BUFFER B B D L EXPANSION TANK INLET LIQUID LEVEL MANUAL TEST CONNECTION E 1/2 (13) J DRAIN & LIQUID LEVEL DRAIN N G R H OUTLET Model A B C D E F G H J K L M N P CAP Dry Wt. Max Full Wt.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. High temperature thermal fluid, steam, and combustible vapors may be vented through the vent connection on the combination deaerator/thermal buffer/expansion tank. 4 CAUTION Non-code tanks cannot be pressurized over 15 psig.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 Pressurized Systems Nitrogen pressurization may be used if the total system content is very large, or in a system operating near or above the vapor pressure of the fluid employed, or if the inlet of the DA tank is not the highest point in the piping system, or at any time to further protect the fluid from oxidation. In conjunction with this system, adhere to the following: 1. An automatic venting device must be fitted to the system expansion tank.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Once the system has been filled, any modification to the tank or connected piping requires purging of the work area to prevent ignition of potentially flammable vapors. Consult factory prior to beginning work.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 ! Catch Tank Adhere to the following for the catch tank: 1. Ensure the heater safety relief valve outlet and connections on the DA tank are piped to a safe catch tank. The catch tank must be appropriately sized based on the system volume and configuration. 2. Under normal operating conditions, the catch tank should be empty. Fluid that is expelled into the tank should not be reintroduced into the system. 3.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. FTCS-IOM-2013-1114 SECTION 2 withstand overpressure equal to the rating of the safety relief valves (normally 100 psig). Thermometers Thermometers should read up to 650°F (343°C).
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 Automatic Fluid Control Valves Because of the widely varied processes in which Fulton Thermal Fluid Heaters are used, it is not possible to provide specific rules for the selection of automatic fluid control valves. Generally, these valves must satisfy the specific materials and construction requirements. The type of operation and design of porting are governed by the degree of control required as well as the particular application.
INSTALLATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Do not attempt to start the equipment for any testing prior to filling and purging the vessel. A dry fire will seriously damage the equipment and may result in property damage or personnel injury and is not covered by warranty.
SECTION 2 INSTALLATION FTCS-IOM-2013-1114 are cold usually indicates sufficient draft. When the unit is running and the stack is hot, the draft should read 0.04 to 0.08 “wc negative. rated for a 1200°F (649°C) operating temperature. 6. Ensure the stack and chimney material complies with all applicable codes. 7. Make adequate provisions for the support of the weight of the chimney and stack to avoid having a load imparted to the outlet connection of the equipment. 8.
INSTALLATION SECTION 2 FTCS-IOM-2013-1114 X X 2' 2' X X X = 3 TO 5 PIPE DIAMETERS ON EACH SIDE OF DAMPER Wrong Wrong Wrong Poor Right: Minimum 1 Pipe Diameter Right Wrong: Less Than 1 Pipe Diameter Wrong FIGURE 19 - BAROMETRIC DAMPER INSTALLATION the building. For heaters equipped with Flue Gas Recirculation (FGR), ducting must be insulated to prevent personnel injury. 11.
OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE PARTS & WARRANTY Questions? Call (315) 298-5121, or visit us online at www.fulton.
OPERATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections of this manual and are qualified to operate/maintain the equipment. Defective or improperly installed equipment is hazardous.
SECTION 3 OPERATION FTCS-IOM-2013-1114 Fill the System The viscosity of thermal fluid is generally very high (500 cS) at ambient temperature. Below 50°F (10°C) some fluids become very thick. Fluid should be in a pumpable liquid form prior to filling the system. Refer to the thermal fluid manufacturer’s recommendations. Adhere to the following when filling the system: 1. Refer to Figure 17 for the drain and fill connection. 1.
OPERATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. FTCS-IOM-2013-1114 SECTION 3 Filling Procedure for Systems Equipped with Inert Blankets Adhere to the following: 1. Follow the instructions in Fill The System section of this manual. 2.
SECTION 3 OPERATION FTCS-IOM-2013-1114 Circulating Pump Adhere to the following: 1. Read manufacturer’s instruction manual thoroughly. If the pump is supplied by Fulton Thermal Corporation, manufacturer’s literature is included with this manual. 2. Never run the pump without fluid in the casing. For pumps equipped with mechanical or air-cooled seals, air must be bled out of the stuffing box area to ensure that thermal fluid has lubricated all seal and bearing areas.
OPERATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Never attempt to operate equipment that has failed to pass all safety checks. This heater is equipped with an ignition device which automatically lights the burner. Do not try to light burner by hand.
SECTION 3 OPERATION FTCS-IOM-2013-1114 Initial Start-Up These instructions are for use when the unit is being started up for the first time, or after prolonged shutdown. They are to be used in conjunction with the specific procedure information in manual section Routine Operation.
OPERATION ! WARNING FTCS-IOM-2013-1114 SECTION 3 Filtering the System Before commissioning the equipment, verify with authorized personnel that the gas lines have been purged. 1. Initially, readings on the gauge will indicate zero or slightly positive pressure. During the first few moments of flow, this reading will go towards vacuum, indicating that the strainer is becoming plugged. Never attempt to operate a heater that has failed to pass all the safety checks. 2.
SECTION 3 OPERATION FTCS-IOM-2013-1114 continue to circulate fluid. 9. When pressures have stabilized, start burner again. 10. Continue in this manner up to the maximum operating temperature. Throughout the initial warm-up, the expansion tank and its overflow pipe must be watched to detect the formation of steam, indicating the presence of water. If this occurs, burner should be shut down. 11. If steam is forcing thermal fluid out of the expansion tank vent, turn the heater off, but leave the pump on.
OPERATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. FTCS-IOM-2013-1114 SECTION 3 providing post-purge of the combustion chamber. 5. The flame is monitored by a flame sensor.
SECTION 3 OPERATION FTCS-IOM-2013-1114 (servo motor) is released to automatic. 4. (Units with Spark Ignition) The spark and oil valves are energized and a timed trial for ignition begins. With the flame proven, the control advances through its main light off sequence, and the ignition shuts off. At this time, with the flame proven, the modulating motor (servo motor) is released to automatic. 5.
OPERATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. FTCS-IOM-2013-1114 SECTION 3 6.
SECTION 3 OPERATION FTCS-IOM-2013-1114 ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
OPERATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.
SECTION 3 OPERATION FTCS-IOM-2013-1114 10. Under Auto/Manual/Off, change the operation to Burner On by using the arrow keys. Press enter and verify that “Burner On” is acknowledged in the current field. 11. Press Escape twice to get back to the main menu. 12. Turn the main burner switch Local or On position. ! WARNING Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. 13.
OPERATION ! WARNING Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. FTCS-IOM-2013-1114 SECTION 3 6. Switch the ON/OFF switch back to ON. The heater will re-start. 7. The light off point for main flame can be set at a higher input than low fire. 8. Press Escape 6 times to get back to the main menu. 9.
SECTION 3 OPERATION FTCS-IOM-2013-1114 8. Verify the flame signal on the display, measure input if gas meter is available. If not, match last elbow pressures and combustion for test fire sheet. Adjust the burner as needed. SETTING LOW FIRE NOTE: As soon as a servo position is altered, the servo will move to that position. Only change servo settings by a maximum of 0.5° at a time before verifying combustion. ! WARNING Non-Fulton product information is for reference purposes only.
OPERATION ! WARNING Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections of this manual and are qualified to operate/maintain the equipment. FTCS-IOM-2013-1114 SECTION 3 9. Once all the points have been verified, press Escape until you are back to the main menu. 10. You can observe the status of the burner by going to OperationalStat >NormalOperation. 11. Turn the main ON/OFF switch to OFF.
SECTION 3 OPERATION FTCS-IOM-2013-1114 Operating Controls The following specifications, data, equipment and operating descriptions apply to typical heaters. These sections are provided for general information purposes only, and do not necessarily reflect the specific details of individual systems. At commissioning, the operation of all safeties and interlocks should be verified.
OPERATION ! WARNING Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer. Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections of this manual and are qualified to operate/maintain the equipment. FTCS-IOM-2013-1114 SECTION 3 2. Reset motor starter; blower should start and purge cycle will begin. 3.
SECTION 3 OPERATION FTCS-IOM-2013-1114 ! of loss of flow. 3. The differential pressure switch can be tested while only the pump is running at operating temperature. Remove the metal cover on top of the switch and increase the setpoint until the pump shuts down. This value should be greater than the DP of the gauges. Next, decrease the setpoint back to its initial value and depress the pump start button to verify the pump will re-start.
OPERATION ! WARNING Do not operate, or allow others to operate, service or repair this equipment unless you (they) fully understand all applicable sections of this manual and are qualified to operate/maintain the equipment. FTCS-IOM-2013-1114 SECTION 3 4. With the unit cold and pump running, lower the high fluid pressure cutout switch until the pump shuts down. Note the setpoint and raise by 10 PSI, then re-start pump. The setpoint at cutout should correspond to the inlet gauge reading. 5.
SECTION 3 OPERATION FTCS-IOM-2013-1114 temperature, note that the temperatures quoted are the actual limit to which any of the fluids may be subjected. It is important to remember that in any fired heater there exists a “film” temperature which is higher than the temperature of the bulk of the fluid. Temperature controllers measure the bulk temperature and not the film temperature. This must be taken into consideration when setting the temperature controls. 3.
OPERATION ! WARNING To ensure that your Fulton equipment is kept operating safely and efficiently, follow the maintenance procedures set forth in this manual. The end user of the heater must maintain all labels on the heater in clean, legible condition. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.
SECTION 3 OPERATION FTCS-IOM-2013-1114 2. The gauge indicating the pressure of the fluid at the inlet is labeled “Inlet“. The “Outlet” gauge indicates the pressure at the outlet, and in effect indicates the resistance of the external pipework circuit. The pressure gauge indicating pressure at the inlet of the pump is labeled “Suction.
OPERATION ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. FTCS-IOM-2013-1114 SECTION 3 Required Pressure Drop Across the Heater The thermal fluid pressure drop across your heater is critical. This should be recorded at the completion of start-up, as follows: 1.
SECTION 3 OPERATION FTCS-IOM-2013-1114 Procedure for First Shutdown The heater system should be shut down after no more than 24 hours of operation at full operating temperature. At this time, the following maintenance items will need to be completed to meet warranty conditions. 1. While pump is still at operating temperature, align circulating pump(s) to pump manufacturer’s specifications. This should be done by means of a dial indicator.
OPERATION FTCS-IOM-2013-1114 SECTION 3 Daily Shutdown 1. Set control switch to “Pump” pump running, burner off. 2. Allow the fluid to circulate for approximately 20-30 minutes and then set the control switch to the “Off ” position. 3. When using fluid cooled pump, continue to circulate cooling water to pumps for 30 minutes after stopping circulation. 4. Open power supply switches. 5.
MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE PARTS & WARRANTY Questions? Call (315) 298-5121, or visit us online at www.fulton.
MAINTENANCE ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose significant health hazards, including but not limited to eye and respiratory system damage.
SECTION 4 MAINTENANCE FTCS-IOM-2013-1114 5. In systems utilizing linkage, check all linkage components for tightness. (Figure 25) 6. In systems utilizing a water cooled thermal fluid circulating pump, check level of lubricating oil in self-leveling reservoir and check cooling water circulation loop for proper operation. See Figure 26.
MAINTENANCE 4 CAUTION All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.
SECTION 4 MAINTENANCE FTCS-IOM-2013-1114 Semi-Annual Maintenance Schedule 1. Pull burner and inspect for heat stress or soot. Clean or replace as necessary. 2. Inspect pilot tube assembly and ignition electrode. Clean or replace if necessary. Reset ignition settings to manual specifications. 3. Inspect internal surfaces of the heater. Inspect refractory for cracks. Cracks larger than ¼” wide will require repair or replacement of the refractory. Inspect coil for sooting.
MAINTENANCE ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. 4 SECTION 4 FTCS-IOM-2013-1114 Soot Cleaning If your coil inspection indicates severe sooting, the following procedure should be followed: 1. Make sure the heater is off and fluid is ambient temperature. 2. Remove the burner and lower access doors. 3.
SECTION 4 MAINTENANCE FTCS-IOM-2013-1114 Differential Pressure Switch With the circulating pump running, observe the difference in pressure between the heater outlet gauge and the heater inlet gauge. Remove the top cover of the differential pressure switch. Note the original setting of the switch. The setpoint should be 2 - 3 psi below the published differential pressure of the heater (this will vary by heater model, refer to Product Data Submittals). See Figure 30.
MAINTENANCE ! WARNING All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations. 4 CAUTION All maintenance procedures should be completed by trained personnel. Appropriate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative.
SECTION 4 MAINTENANCE FTCS-IOM-2013-1114 Troubleshooting Flow Circuit/ Circulating Pump(s) The flow circuit is the electrical circuit that enables the circulating pump(s). Your thermal fluid pump(s) will remain on until the flow circuit opens to disable the pump starter or the Off / Pump / Heat switch is turned to the “Off ” position.
MAINTENANCE burner interlock is the electrical circuit that enables the flame programmer. Your thermal heater needs to have the items in the burner interlock ‘made’ before ignition can occur. Items in the burner interlock may include an air switch, air filter switch, auxiliary blower motor starter contacts, high temperature limit(s), high gas pressure switch, low gas pressure switch, and / or low oil pressure switch. AIR SWITCH All C-model heaters have an Air Switch.
SECTION 4 MAINTENANCE FTCS-IOM-2013-1114 controllers indicate a Pilot Flame Failure by showing as a fault code either Fault 28 for Honeywell 7800 series controllers. Flame Failure PTFI on Fireye E110 series controllers or Fault 9 on Fireye Nexus controls. For electro-mechanical controls, you need to witness when the failure occurs. A Pilot Flame Failure indicates that either a strong enough pilot flame was not generated or the means of sensing the pilot flame strength has failed.
MAINTENANCE FTCS-IOM-2013-1114 SECTION 4 TABLE 10-B - HIGH OUTLET PRESSURE SWITCH TROUBLESHOOTING Problem Potential Remedy An obstruction downstream of the heater Any obstruction downstream of the heater will increase the pressure that the heater outlet sees. This obstruction will generally result from an improper valve setting. Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user).
SECTION 4 FTCS-IOM-2013-1114 MAINTENANCE TABLE 10-D - HIGH INLET PRESSURE SWITCH TROUBLESHOOTING Problem Potential Remedy An obstruction downstream of the heater Any obstruction downstream of the heater will increase the pressure that the heater outlet sees. This obstruction will generally result from an improper valve setting. Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user).
MAINTENANCE FTCS-IOM-2013-1114 SECTION 4 TABLE 10-G - AIR SWITCH TROUBLESHOOTING Problem Potential Remedy Combustion Blower Fan is Dirty If the cups of the squirrel cage type fan become dirty, less air will be moved by the fan. If the fans are dirty enough, there will not be enough air flow for the air switch to prove.
SECTION 4 FTCS-IOM-2013-1114 MAINTENANCE TABLE 10-K - HIGH GAS PRESSURE SWITCH TROUBLESHOOTING Problem Potential Remedy Gas pressure setting on the main regulator is too high With unit running at high fire, make sure that the modulated gas valve is at full open. Since unit lights at low fire, it may be necessary to increase high gas pressure setting or jumper contacts to allow unit to modulate to where modulation gas valve back pressure is lessened.
MAINTENANCE FTCS-IOM-2013-1114 SECTION 4 TABLE 10-N - PILOT FLAME FAILURE TROUBLESHOOTING Problem Potential Remedy Pilot flame strength is inadequate Cycle the unit. During the pilot trial for ignition, carefully observe the pilot flame strength. On Honeywell controllers, the pilot flame strength must be between 1.25 to 5.0 VDC. On Fireye controllers, the pilot flame strength must be greater than 10 VDC.
SECTION 4 FTCS-IOM-2013-1114 Questions? Call (315) 298-5121, or visit us online at www.fulton.
MAINTENANCE 4-18 FTCS-IOM-2013-1114 SECTION 4 © The Fulton Companies 2013
SECTION 5 FTCS-IOM-2013-1114 PARTS & WARRANTY INTRODUCTION INSTALLATION OPERATION MAINTENANCE PARTS & WARRANTY Questions? Call (315) 298-5121, or visit us online at www.fulton.
PARTS & WARRANTY ! WARNING Use of non-factory authorized replacement parts is not recommended for this equipment. Use of non-factory authorized parts may jeopardize safety and system performance, and voids the product warranty. 5-2 FTCS-IOM-2013-1114 SECTION 5 Parts Spare and replacement parts may be ordered from your local representative or through the Fulton Companies. When ordering replacement parts, please have the model number and serial number of your Fulton boiler ready.
SECTION 5 FTCS-IOM-2013-1114 PARTS & WARRANTY Standard Warranty for Fulton Thermal Fluid Heaters WARRANTY VALID FOR MODELS FT-A, FT-C, FT-S, FT-N, FT-HC ONE (1) YEAR (12 MONTH) MATERIAL AND WORKMANSHIP WARRANTY The pressure vessel is covered against defective material or workmanship for a period of one (1) year from the date of shipment from the factory. Fulton will repair or replace F.O.B.
PARTS & WARRANTY 5-4 FTCS-IOM-2013-1114 SECTION 5 © The Fulton Companies 2013
No part of this Installation, Operation, and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies. Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems. © The Fulton Companies 2013 The heat transfer innovators.
