Fulton Electric Thermal Fluid Heaters (FT-N Models) Installation, Operation and Maintenance Manual Serial # __________________________ Model # __________________________ Fulton Order # __________________________ Sold To __________________________ Job Name __________________________ Date __________________________ Fulton Thermal Corp. 972 Centerville Road Pulaski, NY 13142 Telephone: (315) 298-5121 Facsimile: (315) 298-6390 www.fulton.com Fulton Thermal Corp.
Fulton Thermal Corp.
Table of Contents Section 1 – Safety Warnings & Precautions 2. Preparation 3. Filling the System 4. For Systems Equipped with Inert Blankets Section 2 – Installation 5. Circulating Pump 1. Component View 6. Initial Start Up 2. Placement 7. Start Up Service 3. Location 8. Cold Circulation 4. Access 9. Filtering the System 5. Approximate Floor Loadings 10. Energizing the Elements 6. Minimum Clearance 11. Procedure for First Shutdown 7. Circulating Pump 12.
Fulton Thermal Corp.
Section 1 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 1 – Safety Warnings & Precautions Prior to shipment, the following tests are made to assure the customer the highest standards of manufacturing: a) Material inspections b) Manufacturing process inspections c) ASME welding inspection d) ASME hydrostatic test inspection e) Electrical components inspection f) Operating test g) Final engineering inspection h) Crating inspection Rigging your heater into position should be handled by a competent rigger experienced in handling heavy equipment.
WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. - Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliances. - WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch; do not use any phone in your building. Immediately call your gas supplier from a neighbor’s phone.
Max. operating temperature for air cooled pumps varies by manufacturer. Consult instruction manual to verify. Note Non-code tanks cannot be pressurized over 15 psig. Note If the tank is located outdoors nitrogen is required. Warning High temperature thermal fluid, steam and combustible vapors may be vented through the DA vent connection.
Note Do not use system circulating pump for system filling. Note A pump that has been used for water or a different thermal fluid should not be used prior to extensive cleaning. Thermal fluid can be damaged by contact with moisture or other fluids. Warning Pressurizing a drum to force fluid into the system is not recommended. The drum can easily explode, creating a hazard to personnel and equipment. Note Tanks are non-code as a standard. Non-code tanks cannot be pressurized over 15psig.
Fulton Thermal Corp.
Fulton Thermal Corp.
Section 2 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 2 – Installation 1. Component View Fulton Thermal Corp.
2. Placement a) Proper placement of your Fulton Thermal Fluid Heater is essential. Attention paid to the following points will save a great deal of difficulty in the future. Correct placement is the first step to trouble-free installation, operation and maintenance. 3. Location a) Authorities with jurisdiction over any national or local codes which might be applicable to thermal fluid applications should be consulted before installations are made.
a) Free standing figures take the weight of the heater alone into consideration. Floor loadings for skid mounted units vary with configuration.
7. Circulating Pump a) 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 found in Section 5 of this manual. b) Location 1. The pump should be located adjacent to the heater. Its base must be firm, level (preferably concrete), and free from vibration.
valve. See that pipe work connections match up accurately with pump flanges. Refer to the pump manufacturer’s recommendations for the specific pump inlet piping requirements. Typically these requirements are that: a. It be a straight run of pipe. b. The straight run from the pump inlet to the first fitting, valve, or flex connector be a minimum of 6-10 pipe diameters in length. c. The pipe used should be the same size as the inlet of the pump. 3.
d) Typical Fulton Thermal Piping Schematic 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
f) Lubrication 1. 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. An air cooled pump has a grease nipple located at the drive end of the pump near the coupling connection. This comes pre-greased, and should be greased at intervals as recommended by the manufacturer. 2. An oiler is shipped with each water cooled pump and it should be filled with a lubricating oil recommended by the manufacturer.
i) Water Cooling 1. A throttling needle valve should be installed on the inlet side of the water cooling passages and adjusted so that the outlet water is between 120°F. and 160°F. Typically this means a flow rate of 2-5 GPM at 40°F inlet temperature. Consult pump manufacturer’s specifications for dimensions of water cooling connection. 2. The throttling valve on a water cooled pump is designed to automatically give the proper flow rate for a 40 PSIG or greater supply. 3.
8. Combination Expansion/Deaerator/Thermal Buffer Tank a) Fulton Thermal’s efficient design combines the operation of the expansion, deaerator, and thermal buffer tanks. Installation is considerably simplified by virtue of this arrangement. b) Expansion Section 1. The expansion section is vital to the thermal fluid system. From ambient to operating temperature, the thermal fluid in the system will typically expand in the range of 30%, and a vessel capable of handling this expansion is mandatory.
overflow. At initial fill (for system volume calculations) the deaerator and cold seal sections must be filled completely and the expansion section must be filled to a level of 4 inches to "make" the liquid level switch. 2. The volume between the initial fill level and the safe "full" level is the amount available for expansion. That volume is used to decide which tank is suitable for the system expansion. f) Sizing Example 1. A system contains 175 gallons, including the heater, but not the tank.
Model Capacity Initial Fill Available for Max System (Gallons) (Gallons) Expansion Volume (Gallons) FT-200-L 52 25 46 184 FT-500-L 132 40 121 525 FT-1000-L 264 80 232 1000 FT-1500-L 397 90 380 1400 FT-2000-L 528 145 444 1700 FT-3000-L 793 215 717 2600 FT-5000-L 1310 300 1168 4600 9.
Liquid Level Switch 10. Connections a) The vent connection must be made in a manner that will prevent penetration of water or foreign bodies into the tank. This connection must always terminate in a safe, well ventilated area and has to be free of obstruction, open to atmosphere, and arranged in such a manner that, in the event of discharge from the system, thermal fluid could drain into a catch tank without danger to personnel or property. Note Non-code tanks cannot be pressurized over 15 psig.
d) The connection between the tank outlet and the horizontal pump inlet run should be as close to a vertical drop as possible. It should not contain an excessive number of bends of length of pipe. These faults could encourage pump cavitation. e) As noted, the inlet to the deaerator must be higher than or equal to the highest point in the system or a pressurized system must be used.
vapors. Consult factory prior to beginning work. Consult MSDS for your thermal fluid for flammability limits. n) Electrical Connections Fulton Thermal Corp.
1. A wall-mounted, fused disconnect sized for the unit must be provided and fitted by the client/contractor, if a disconnect is not supplied on the panel. 2. Fuses must be sized according to motor name plates and local electrical codes. 3. Heaters and single skid systems are generally shipped completely prewired. The liquid level switch on the expansion tank, when supplied, will be shipped in the parts box and must be installed in the field. Multiple skid systems may require wiring between the skids. 4.
construction, proper flanging, gaskets, and other appropriate means of eliminating potential leakage must be employed. 12. General a) All components exposed to thermal fluid flow, including pipe, valves, and screens, must not be made out of copper, copper alloys, aluminum, or cast iron. Cast iron is porous to thermal fluids, and copper and aluminum act as catalysts in the degradation of some thermal fluids. Carbon or stainless steel, or ductile iron, are recommended.
c) Supports and anchors must be provided for all pipes where necessary to prevent undue stresses from being placed on items of equipment, including pumps, valves, and the heater. Supports and anchors which will not interfere with thermal expansion should be chosen. d) All pipe joints should be of either welded or flanged construction. Screwed joints must be avoided where possible. In no instance should screwed joints be used in the flow circuit. e) All flanges should be welded to the pipe and not screwed.
Bolting Sequence for 4 and 8 Bolt Flanges Fulton Thermal Corp.
Standard gaskets supplied by Fulton are JM Clipper Elastograph for operating temperatures up to 650oF. Recommended Loads for JM Clipper elastograph 150# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 4 5 6 8 10 Number of Bolts Diameter of Bolts Inches Preferred Torque Required per Bolt Ft-Lbs.
where the piping is first soaked in an acid bath, then soaked in a neutralizing bath, then given a protective oil coating.) d) All pipes should be installed with a pitch to facilitate draining and venting. Note Inspect the system daily for leaking joints. Shut the system down and tighten any leaking flanges or connects immediately. 17. System Connections a) If screwed connections have to be made, e.g.
Recommended Loads for Flexitallic Spiral Wound Class 300# Gaskets SAE Grade 5 Bolts (typical) or Equal Nominal Flange Size Inches 1/2 3/4 1 1¼ 1½ 2 2½ 3 3½ 4 5 6 8 10 Number of Bolts Diameter of Bolts Inches Preferred Torque Required per Bolt Ft-Lbs. 4 4 4 4 4 8 8 8 8 8 8 12 12 16 1/2 5/8 5/8 5/8 3/4 5/8 3/4 3/4 3/4 3/4 3/4 3/4 7/8 1 45 90 90 90 150 90 150 150 150 150 150 150 240 368 Note The system pump is not to be used to fill the system.
c) A safety relief valve may be shipped in the parts box accompanying the fuel-fired heater, and must be installed in the outlet manifold. On all units, the outlet must be piped to a safe discharge area. The piping from the outlet of the safety valve must be piped to a catch tank. The discharge flow must not be restricted, i.e. no valve should be installed. The weight of the piping must be properly supported in order to prevent damage to the safety valve.
and packed with Grafoil packing or equal. The valves should have a back seating to allow re-packing without draining the system. In all units, a “Y” type strainer should be installed in the fluid return line, between the deaerator tank and the circulating pump. e) As previously stated, this strainer is provided on all skid-mounted units. Valves must be provided (unless the heater has been skid-mounted with the tank) so that the strainer can be isolated for cleaning of the element.
2. If the process flow will vary with the system load, a suitable bypass system can be recommended by Fulton Thermal Corporation. 21. Testing a) Upon completion of the installation, a pneumatic test not exceeding 15 psig should be conducted. Soap tests should be made at all welds and joints to ensure that the system is free from leaks. b) Under no circumstances should the system be filled with water. Make sure that the air supply is as free from moisture as possible.
pressure in the system yields many advantages, a false sense of security should not be allowed to develop on account of this alone. c) Certain types of thermal fluid may have operating temperatures reaching 650°F (345°C) and above, so all exposed pipework is hazardous and should be insulated, as indicated in the preceding sections. d) Flanged joints must be checked for tightness during and after the first warming up of the system.
5. Special care must be taken when consulting fluid manufacturers’ literature, as maximum fluid 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. 6. It is the BULK fluid temperature and NOT the FILM temperature that is indicated by the instruments. 7.
Note Fulton Thermal Corporation cannot be held responsible in the case of accident or damage resulting from the use of inadequate fluid. i) Routine Analysis of Heat Transfer Fluid 1. Nearly all leading manufacturers of heat transfer fluids provide an after sales service to monitor the condition of the fluid in operation and make recommendations when replacement becomes necessary. 2. Each fluid manufacturer has procedures for regular testing and analysis of the fluid.
4. Exceeding the maximum operating temperature of the thermal fluid will 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. Fulton Thermal Corp.
Section 3 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 3 – Operation 1. Start-Up Preparation & Installation Review a) Check with local authorities where approval for start-up is required. In some localities, final inspection of services may be required. b) Review the installation section of this manual carefully. Confirm accordance with installation guidelines, including: 1. In general, ensure that the heater area is in conformance with established heater room requirements. Review national and local codes. 2.
Some plastics can be dissolved by thermal fluid. Note Do not use system circulating pump for system filling. Note A pump that has been used for water or a different thermal fluid should not be used prior to extensive cleaning. Thermal fluid can be damaged by contact with moisture or other fluids. Warning Pressurizing a drum to force fluid into the system is not recommended. The drum can easily explode, creating a hazard to personnel and equipment. Drain and Fill Connection d) Filling Procedure 1.
liquid level switch, manually trip the liquid level switch. Unit should shut down; pump will stop. 4. For Systems Equipped with Inert Blankets a) Follow the instructions listed under “Filling The System”. b) Pay close attention to notes and warnings. c) Inspect the system to be sure all valves are open and all drains are closed. d) Open all high point air vents. e) Do not pressurize the system with nitrogen at this point. f) Inspect the liquid level switch and be sure the switch is functioning properly.
b) The pump should never be run 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 of the pump even a short time without bleeding first will damage the pump. c) Also use the thermal fluid as a barrier fluid. Remove the 3/8” plug at the barrier fluid fill port. Fill the cavity with thermal fluid until it comes out of the overflow tube.
7. The pump should not be subjected to thermal or pressure shock. The thermal fluid should, therefore, be allowed to flow into the casing slowly. 8. Check field work and make sure that all connections have been made in the proper places. Check electrical connections to the motor. 9. Rotate the pump shaft by hand to be sure there is no binding or rubbing within the pump or driver. Correct any problems immediately. 10. Check to see that pump is properly aligned while cold. 11.
d) Careful preparation can expedite the commissioning of your heater. Most delays can be avoided by following the instructions in this manual. Failure to complete required procedures properly can result in the need for further service time, at extra cost to the customer. e) Service people will not commence start-up if there are obvious system deficiencies. However, start-up service in no way constitutes a system design check or approval of the installation.
a) Initially, readings on the compound 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. b) Typically, a reading of 3” Hg or greater vacuum on the pump suction gauge indicates that the strainer must be cleaned. The strainer screen should be back flushed or pulled, cleaned and replaced. c) Strainers should be cleaned by means of compressed air.
Illustration indicates proper fluid level in the expansion section of the deaerator tank. Fulton Thermal Corp.
10. Energizing the Elements Pressure Gauges a) When the system is initially brought up to temperature, additional pipe scale and welding slag will loosen and enter the fluid stream. This will be trapped in the strainer causing vacuum at the pump suction. This procedure must be followed as necessary in the course of heater operation. b) Check safeties. c) Place three position switch in Position “2”. Elements will begin to cycle on. d) Check gauges indicating pump and circuit pressures.
h) If no liquid level switch is provided on the expansion tank, open the low level manual test connection regularly while brining the unit up to temperature. If a permanent flow of fluid does not result when this valve is opened, stop the heater and the pump and add more thermal fluid to the system. Use only the exact same brand and type of fluid initially used to fill the system. i) Once up to temperature, check the fluid level in the expansion section by opening the high level manual test connection.
c) In the event of an abnormal reading, contact Fulton Service immediately. Failure to take immediate action in the event of reduced fluid flow may result in rapid and serious degradation of the fluid, with possible damage to the heater. 13. Required Flow Through The Heater a) Maintenance of sufficient flow through the thermal fluid heater and system at all times of operation is critical. See table for recommended standard flow rates. b) Note pressure gauge readings at start-up.
heater. The differential pressure switch will shut the unit down in the event of loss of flow. 2. The differential pressure switch can be tested while only the pump is running. Remove the metal cover on top of the switch and increase the setpoint until the pump shuts down. Next, decrease the setpoint back to its initial value and depress the pump start button to verify the pump will re-start. d) Pump Motor Starter 1. While firing, actuate the manual trip button on the pump motor starter.
3. Temperature controllers measure the bulk temperature and not the film temperature. This must be taken into consideration when setting the temperature controls. 4. These approximate guidelines for temperature settings are not to override the system design parameters. 5. These instructions should be used with information from the system designer. Manufacturer’s literature on the temperature controller is provided in the last section of this manual. 6.
h) Operating Limit Controller 1. The limit controller is mounted in the panel box door. This limit controller senses temperature in the outlet manifold. The temperature setpoint in the controller can be adjusted following instructions in the component data sheet section of this manual. i) Pressure Gauges 1. All units have two pressure gauges measuring the thermal fluid pressure at the inlet of the heater and at the outlet of the heater.
signal strength from flame programmer or testing device. Operator attendance during warm-up is a recommended precaution. j) Start-up is considered complete when the unit begins to throttle back or shutdown on target temperature. 16. Daily Shutdown a) Set control switch to “Pump” pump running, burner off. b) Allow the fluid to circulate for approximately 20-30 minutes and then set the control switch to the “Off” position.
Fulton Thermal Corp.
Section 4 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 4 – Maintenance Minimum equipment necessary to start and maintain fuel-fired thermal fluid heaters: Digital Multimeter 1. Required Maintenance at First Shutdown a) The thermal fluid system should be shut down after no more than 24 hours of operation at operating temperature. At this time, the following maintenance items will need to be completed to meet the condition of warranty. b) While pump is still at operating temperature, align circulating pump(s) to pump manufacturer specifications.
Monthly a) Manually check fluid level in the expansion tank. Drain ½ gallon of thermal fluid from the expansion tank. If water is present, continue to drain ½ gallon until no water is present. b) Check operation of all safeties. Refer to the instructions at the end of this section. c) Review daily log sheets noting any deviations from the norm. d) Check the tightness of all couplings, including the fuel oil pump drive (oil-fired units), fan impeller, circulating pump, etc. Fulton Thermal Corp.
Semi-Annually a) Review daily log sheets noting any deviations from the norm. Annually a) Clean all strainers in the thermal fluid system. b) Take a one quart sample of thermal fluid and return to the thermal fluid manufacturer for analysis. c) Schedule to local Fulton representative or factory service technician to perform an annual preventative maintenance. 3. Maintenance Procedures Lubrication a) Different motor manufacturers recommend various intervals for lubrication schedules.
Differential Pressure Switch Low Inlet Pressure Switch a) Slowly close the valve on outlet of main circulating pump observing heater inlet pressure gauge. Note the pressure at which the switch trips. This pressure should be roughly the set point of the switch minus any differential that is set. High Outlet Pressure Switch a) Note the original setting of the switch and turn adjustment screw counterclockwise while observing heater outlet pressure gauge until switch trips.
High Outlet Pressure Switch Temperature Limit(s) a) Adjust set point(s) of temperature limit(s) down to a point lower than the PV (process variable is typically the current fluid temperature at the heater outlet). Solid-state controls will deactivate a control relay powering a set of n.c. contacts in the interlock circuit. Analog controls will open their contacts in the interlock circuit. Trip temperature should be within 5 degrees of PV temperature.
a) Review log sheets and note any deviations from the norm. Annually a) Clean all the strainers in the thermal fluid system. b) Take a quart sample of thermal fluid and have it analyzed per fluid manufacturers instructions. c) Schedule the local representative or factory technician to perform preventative maintenance on the system. Note All of the above maintenance procedures should be completed by trained personnel.
2. A "Pump Suction" gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning. Generally this point is between 0 and -5" Hg. 3. If the strainer is plugged, isolate the strainer and drain that section of piping being mindful of the temperature of the thermal fluid. 4. Remove the strainer and clean with compressed air, high-pressure water or a cleaning solution. Replace and observe new pump suction pressure. e) Failed circulation pump coupling 1.
installations have block valves at the heater to facilitate safe isolation and cleaning of the sensing line. i) Improper switch setting 1. The Low Inlet Pressure Switch should be set at 5 psi less than the pressure read on the heater inlet pressure gauge at full operating temperature of the system. j) Faulty Switch 1. If pressure is verified and reads correctly above set point on switch and the sensing line to the pressure switch is open, the pressure switch is faulty.
m) Improper switch setting 1. The High Outlet Pressure Switch should be set at 5 psi over than the maximum pressure read on the heater outlet pressure gauge during proper operation at the coldest ambient temperature expected. n) Faulty Switch 1. If pressure is verified and reads correctly below set point on switch and the sensing line to the pressure switch is open, the pressure switch is faulty. Replace switch, set for desired set point and test for proper operation. o) Flow Switches 1.
compressed air, high-pressure water or a cleaning solution. Replace and observe new heater inlet pressure. c) Failed circulation pump coupling 1. A failed coupling will result in a decreased or no flow condition through the heater. The coupling can be checked by removing the coupling guard between the pump and pump motor. The coupling should not be torn or misshapen.
2. Observe heater outlet pressure at temperature with all users / heat exchangers calling for heat (100% user). Observe heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100% bypass). 3. Bypass regulating valve(s) should be adjusted to equal flow condition through users. Call or e-mail Fulton for further details. 4. It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced. b) Improper switch setting 1.
b) Plugged circulation pump strainer basket 1. A plugged strainer will result in a decrease in flow through the heater. High vacuums developed from plugged strainers can also stress the seals of the pump causing the pump to fail. 2. A "Pump Suction" gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning. Generally this point is 5-10 psi (10-20 in. Hg). 3. If the strainer is plugged, isolate the strainer and drain being mindful of the temperature of the thermal fluid.
Call For Heat a) The call for heat circuit is the circuit that enables burner operation. Fulton Thermal Corporation has used a variety of Temperature Controllers to act as the Call for Heat. b) Generally these controls work in combination with a control relay. When the Temperature Controller calls for heat, a signal is sent to the coil of a control relay that closes a normally open set of contacts in series with the burner circuit.
needs to be replaced. If the coil shows resistance, energize coil and check contacts. With coil energized, normally open contacts should close resulting in a reading of control voltage on both the common and normally open contact. c. If voltage exists on common but not on normally open contact either switch contacts if another set of normally open contacts are available or replace relay. Safety Interlock a) High temperature limit 1. All thermal fluid heaters have at least one High Temperature Limit.
7. Fulton Thermal Fluid Heater Log Sheet Fulton Thermal Corp.
Fulton Thermal Corp.
Section 5 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 5 – Parts & Warranty Part Number Description Approx. Weight Lead lbs. kgs. Time CONTROLS Differential/Flow Switches 2-30-000454 UE H105K14727 Differential Pressure Switch 4.0 1.82 Stock 2-30-000448 UE H105K456 Differential Pressure Switch-2-20-psi 4.0 1.82 Stock 2-30-000453 1/4” Needle Valve (block valve) 1.0 0.46 Stock 2-35-000330 Swedgelock-straight 0.025 Stock 2-35-000329 Swedgelock-90deg. 0.
Deaerator Tank Parts 2-30-000551 Liquid Level HG34 4.3 1.95 Stock 2-30-000552 NEMA 4 Liquid Level HW34 10.32 4.69 Stock 2-30-000553 Explosion Proof HR34 10.36 4.71 Stock 2-40-000730 Liquid Level Switch L4 High & Explosion Proof 4.22 1.
2-22-000046 Lockwasher-5/16” 0.03 0.
2-45-000244 Fuse Block J600-603C Stock 2-45-000344 Fuse Block J60100-3CR Stock 2-45-000006 SC-40 Fuse (240V) 0.1 0.05 Stock 2-45-000007 SC-50 Fuse (240V) 0.1 0.05 Stock 2-45-000008 SC-60 Fuse (240V) 0.1 0.05 Stock 2-45-000276 16 Amp Disconnect Stock 2-45-001050 25 Amp Disconnect Stock 2-45-001051 40 Amp Disconnect Stock 2-45-001052 60 Amp Disconnect Stock Gaskets & Material 2-60-000114 Silicone Sealant - red - 10 oz. 0.82 0.
2-12-000403 3/4” 300# Gasket 0.1 0.05 Stock 2-12-000405 1” 300# Gasket 0.12 0.05 Stock 2-12-000407 1-1/4” 300# Gasket 0.14 0.06 Stock 2-12-000409 1-1/2” 300# Gasket 0.18 0.08 Stock 2-12-000411 2” 300# Gasket 0.18 0.08 Stock 2-12-000413 2-1/2” 300# Gasket 0.26 0.12 Stock 2-12-000415 3” 300# Gasket 0.3 0.14 Stock 2-12-000417 4” 300# Gasket 0.44 0.2 Stock 2-12-000419 5” 300# Gasket 0.54 0.25 Stock 2-12-000421 6” 300# Gasket 0.6 0.
Motor Contactors-3 Phase/120V coil-Siemens 2-40-000878 3RT1015-1AK6 Contactor-7amp 0.8 0.36 Stock 2-40-000567 3RT1016-1AK6 Contactor-9amp 0.8 0.36 Stock 2-40-000642 3RT1017-1AK6 Contactor-12amp 0.8 0.36 Stock 2-40-000643 3RT1025-2QB0 Contactor-17amp 0.8 0.36 Stock 2-40-000644 3RT1026-1AK6 Contactor-25amp 0.8 0.36 Stock 2-40-000646 3RT1035-1AK6 Contactor-40amp 0.8 0.36 Stock 2-40-000825 3RT1036-1AK6 Contactor-50amp 0.8 0.
PUMPS Allweiler Unmounted Pumps 2-30-001680 NTT 32-160 w/ Mechanical Seal * 2-30-001041 NTT 32-200 w/ Mechanical Seal * 2-30-001681 NTT 40-160 w/ Mechanical Seal * 2-30-001020 NTT 40-200 w/ Mechanical Seal * 2-30-001021 NTT 50-160 w/ Mechanical Seal * 2-30-001684 NTT 50-200 w/ Mechanical Seal * 2-30-001022 NTT 50-250 w/ Mechanical Seal * 2-30-001685 NTT 65-160 w/ Mechanical Seal * 2-30-001036 NTT 65-200 w/ Mechanical Seal * 2-30-001035 NTT 65-250 w/ Mechanical Seal * 2-30-00103
2-30-001200 433.2 Mechanical Seal 0.4 0.18 Stock 2-30-001038 210.1 Shaft 3.0 1.36 Stock 2-30-001204 321.3 & 321.4 Ball Bearing 1.42 0.65 Stock 2-30-001058 Complete 470 Bearing Frame 53.84 24.47 Stock 2-60-000153 EP #2 Grease 10.14 4.61 Stock Dean’s –Unmounted Pump-includes impeller (truck ship only-call for impeller trim size) 2-30-002000 RA3000 1-1/2x3x8-1/2 260.0 118.0 Stock 2-30-002002 RA3000 2x3x8-1/2 260.0 118.0 Stock 2-30-002004 RA3000 3x4x8-1/2 344.0 156.
2-30-002235 #3 Impeller - 1-1/2x3x8-1/2 8.7 4.0 Stock 2-30-002236 #3 Impeller - 2x3x 8-1/2 10.3 4.7 Stock 2-30-002237 #3 Impeller - 3x4x8-1/2 11.1 5.1 Stock 2-30-002238 #3 Impeller - 4x6x 8-1/2 12.6 5.8 Stock MISC Part #3 Impeller - 1.5x3x10 2-30-002239 #77 Casing Gasket 0.04 0.02 Stock 2-30-002240 6322595 Grease 0.2 0.1 Stock 8-00-000046 Shaft Sleeve Guide 1.0 0.05 Stock 8-00-000047 Carbon Sleeve Removal Tool 1.6 0.
2-30-000693 5020-30 Impeller 210 mm 6.14 2.79 2-30-000694 4016-30 Impeller 170 mm 3.94 1.79 Miscpart 10020 Impeller Pump serial number must be given to factory to verify Factory Consult Factory Consult Factory Consult Factory availability & pricing. Common Parts for the Following Models: 3213; 3216; 3220; 4013; 4016; 4020; 5013; 5016; 5020; 6513; 6516; 6520 and 8016 4-30-000108 Mech Seal Kit (3213 to 8016) 1.7 0.8 Stock 4-30-000110 Pump Repair Kit w/mech seal (3213 to 8016) 2.0 1.
2-60-000153 EP #2 Grease 10.14 4.61 Stock Pump/Motor Coupling Parts 2-30-000707 E4 24mm Rexnord Hub 1.8 0.82 Stock 2-30-000705 E4 1-1/8” Rexnord Hub 1.45 0.66 Stock 2-30-000706 E4 1-3/8” Rexnord Hub 1.22 0.55 Stock 2-30-000710 E4 1-5/8” Rexnord Hub 0.96 0.44 Stock 2-30-000708 E4 Elastomer Element 1.36 0.62 Stock 2-30-000704 E5 24mm Rexnord Hub 2.84 1.29 Stock 2-30-001072 E5 32mm Rexnord Hub 2.4 1.09 Stock 2-30-000712 E5 1-1/8” Rexnord Hub 2.52 1.
2-30-000612 2-30-000613 Kunkle Safety Valve 1-1/2” 100 psi-920-300#flanged Kunkle Safety Valve 2” 100 psi-920--300#flanged 34.0 15.5 Stock 45.0 20.
2-30-000883 1.5” Dezurik Valve Repair Kit 0.2 0.1 2-30-001261 ES10 Actuator Rebuild Kit 0.2 0.1 2-30-001260 ES20 Actuator Rebuild Kit 0.16 0.07 2-30-001276 1” Valve Actuator ES10-6 Factory Consult Factory Consult Factory Consult Factory Consult Factory SteamPac Components 2-40-000420 Fulton Pump Relay - 120V 0.5 0.23 Stock 2-40-000422 Base for Fulton Pump Relay (8 pin) 0.25 0.11 Stock 2-40-000403 IDIDO Relay 2.0 0.91 Stock 2-40-000202 Motor Starter R4243 - 30amp 0.52 0.
2-30-000830 Gasket for 8” Keckley Stainer 0.14 0.06 Stock 2-30-000627 Strainer -4” Keckley 150# Flanged 62.2 28.3 Stock 2-30-000874 Strainer -5” Keckley 150# Flanged 2-30-000875 Strainer -6” Keckley 150# Flanged 68.5 34.3 Stock 2-30-000828 Strainer -8” Keckley 150# Flanged 999.0 454.
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.
Fulton Thermal Corp.
Section 6 Fulton Thermal Corp.
Fulton Thermal Corp.
Section 6 – Product Specs & Data Fulton Thermal Fluid Electric Heat Transfer Systems 1. General Description a) Contractor shall furnish and install a ___________KW BTU/Hr. electric thermal fluid heat transfer system per plans. The system shall be "Fulton" as manufactured by Fulton Thermal Corporation, Pulaski, New York.
9. Heater outlet pressure gauge – Fulton 10. ASME Certified safety relief valve - Kunkle Model 920 11. Fused magnetic contactors for electric elements 12. Magnetic starter for thermal fluid circulation pump 13. Step controller for sequential control of elements - Solitec Note: an SCR is an available option 14. Three Position Selector Switch: Off/Pump On/Heater On 15. Four Indicating Lights: 1. Power 2. Pressure & Flow 3. Heat Demand 4. Alarm 16. Low flow interlock 17. Non-fused disconnect 18.
650°F and shall be supplied complete with motor starter for proper motor HP, voltage and cycles. 8. Tests a) Shall include a hydrostatic test of the pressure vessel in the presence of an inspector having a National Board Commission. He shall certify a Data Report which shall be delivered with the heater as evidence of ASME Code compliance. In addition to ASME symbol, the heater shall bear a National Board Registration Number.
Dimensions and Sizing Instructions of the Fulton Combination Expansion/Deaerator/Thermal Buffer Tank Models FT-200-L to FT-5000-L Fulton Thermal Corp.
Developed specifically for thermal fluid system use, the Fulton Combination/Deaerator/Expansion/Thermal Buffer Tank is a patented design. The unique combination of the operation of these three vessels in one results in numerous advantages including: pipework simplification, protection of thermal fluid from oxidation, ease of installation, and continuous deaeration of fluid, avoiding pump cavitation. Expansion Section: The expansion section is vital to the thermal fluid system.
A system of interconnecting pipework in the thermal buffer tank section prevents the movement of any oil, that has not cooled sufficiently, into the expansion section. This avoids contact of very high thermal fluid temperature with oxygen contained in the atmosphere. Sizing the Tank for the System: Expansion tank capacity is the total volume of the tank. It is necessary to have some air space available at the tope of the tank to avoid spillage or overflow.
Specifications-Vertical Electric Thermal Fluid Heater 0075 0150 0225 0300 0375 0430 0640 0860 1070 1290 1500 1720 KW 22 44 66 88 110 126 189 252 315 378 441 504 1000 BTU/HR 75 150 225 300 375 429 644 859 1074 1289 1504 1719 18.9 37.8 56.7 75.6 94.5 108 162 216 271 325 379 434 Model FT-N Heat Input 1000 KCAL/HR Heat Output 1000 BTU/HR 1000 KCAL/HR 74 148 222 294 368 420 631 842 1053 1263 1474 1685 18.6 37.3 59.9 74.1 92.7 105.8 159 212.
Dimensions-Vertical Electric Thermal Fluid Heater 0075 0150 0225 0300 0375 IN 1.5 1.5 1.5 1.5 1.5 2 2 2 2 2 2.5 2.5 MM 38 38 38 38 38 51 51 51 51 51 63.5 63.5 Model FT-N 0430 0640 0860 1070 1290 1500 1720 Heater Inlet/Outlet Connections (A) Overall Height IN MM 70 70 70.5 70 70 90.5 90.4 90.8 89.8 91.
Fulton Thermal Corp.
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. Fulton Thermal Corp.
