Fulton Vertical Tubeless User Manual

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Page 1

INSTALLATION AND

OPERATION MANUAL

Vertical Tubeless Design

Thermal Fluid Heaters

Model FT-A

Serial/National Board #

Model

Fulton Order

Sold To

Job Name

Date

FTA-IOM-2013-0227

Page 2

Page 3

FTA-IOM-2013-0227 TABLE OF CONTENTS

Introduction 1-1

Overview .............................................................................................................. 1-2

Warnings & Cautions ............................................................................................1-2

Disclaimers and Local Codes ................................................................................1-2

Installation 2-1

Placement & Rigging ........................................................................................... 2-2

Clearances & Serviceability .................................................................................. 2-3

Environment, Ventilation and Combustion Air Requirements ............................ 2-3

Utilities .................................................................................................................2-7

THE GAS SUPPLY ..........................................................................................................................27

THE OIL SUPPLY ...........................................................................................................................27

Instrument Air ......................................................................................................2-8

Electrical Supply ................................................................................................... 2-8

Thermal Fluids .................................................................................................... 2-10

THERMAL FLUIDS AT ELEVATED TEMPERATURES ....................................................................210

SELECTING A THERMAL FLUID ..................................................................................................211

ROUTINE ANALYSIS OF HEAT TRANSFER FLUID ........................................................................212

THERMAL FLUID BREAKDOWN .................................................................................................212

Piping Speci cations .......................................................................................... 2-14

Insulation ........................................................................................................... 2-20

System Interfaces ............................................................................................... 2-20

HEATER CONNECTIONS ..............................................................................................................220

THERMAL FLUID CIRCULATING PUMP .....................................................................................220

REQUIREMENTS FOR AIR COOLED PUMPS ..............................................................................222

REQUIREMENTS FOR WATER COOLED PUMPS .........................................................................222

COMBINATION DEAERATOR/THERMAL BUFFER/EXPANSION TANK ........................................222

SIZING THE EXPANSION TANK FOR THE SYSTEM ......................................................................223

PRESSURIZED SYSTEMS ............................................................................................................223

VENT CONNECTIONS ..................................................................................................................226

CATCH TANK ...............................................................................................................................227

DRAIN/FILL CONNECTION .........................................................................................................227

PRESSURE GAUGES ...................................................................................................................227

THERMOMETERS .......................................................................................................................227

VALVES .......................................................................................................................................228

AUTOMATIC FLUID CONTROL VALVES .......................................................................................229

BYPASS VALVES ........................................................................................................................229

Assembly of Fulton Multi-Skid Engineered Systems .........................................2-30

Stack and Flue ....................................................................................................2-31

Testing ................................................................................................................ 2-32

Operation 3-1

Start-Up Preparation & Installation Review ........................................................ 3-2

Fill the System ...................................................................................................... 3-2

FILLING PROCEDURE FOR SYSTEMS OPEN TO ATMOSPHERE ....................................................33

FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS .................................33

Circulating Pump .................................................................................................. 3-4

PUMP WITH MECHANICAL/AIR COOLED SEAL ...........................................................................35

PUMP WITH PACKED SEAL ..........................................................................................................36

Start-Up Service ................................................................................................... 3-6

Initial Start-Up ..................................................................................................... 3-6

COLD CIRCULATION......................................................................................................................36

FILTERING THE SYSTEM ...............................................................................................................37

BOILOUT .......................................................................................................................................38

COMBUSTION ...............................................................................................................................39

Flame Programmers ..........................................................................................3-12

Operating Controls .............................................................................................3-12

LIQUID LEVEL SWITCH  WHEN COMBINATION TANK IS SUPPLIED ........................................312

AIR SAFETY SWITCH ..................................................................................................................312

BLOWER MOTOR STARTER .........................................................................................................313

PUMP MOTOR STARTER .............................................................................................................313

DIFFERENTIAL PRESSURE SWITCH ...........................................................................................313

HIGH AND LOW FLUID PRESSURE SWITCHES ...........................................................................314

GAS PRESSURE SWITCH ............................................................................................................315

OPERATING TEMPERATURE CONTROLS ....................................................................................315

HIGH TEMPERATURE LIMIT SWITCHES SAFETY ......................................................................316

OPERATING LIMIT CONTROLLER ...............................................................................................317

ON/OFF CONTROLS ....................................................................................................................317

MODULATING CONTROLS ..........................................................................................................317

PRESSURE GAUGES ....................................................................................................................317

TEST OF IGNITION SAFETY SYSTEM SHUTOFF ..........................................................................318

CYCLE TESTING ...........................................................................................................................318

Required Pressure Drop Across the Heater .........................................................3-18

Procedure for First Shutdown ............................................................................3-19

Daily Start-Up ..................................................................................................... 3-19

Daily Shutdown ..................................................................................................3-20

Before Leaving the Installation .......................................................................... 3-20

Maintenance 4-1

Required Equipment ............................................................................................ 4-2

Required Maintenance at First Shutdown ........................................................... 4-2

Daily Maintenance Schedule ................................................................................ 4-2

Weekly Maintenance Schedule ............................................................................4-3

Monthly Maintenance Schedule .......................................................................... 4-3

Semi-Annual Maintenance Schedule .................................................................. 4-4

Annual Maintenance Schedule ........................................................................... 4-4

General Maintenance Procedures ....................................................................... 4-5

LUBRICATION ...............................................................................................................................45

SOOT CLEANING ..........................................................................................................................45

Safety Check Procedures ..................................................................................... 4-5

LIQUID LEVEL SWITCH ................................................................................................................45

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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Page 4

TABLE OF CONTENTS FTA-IOM-2013-0227

STACK LIMIT .................................................................................................................................45

DIFFERENTIAL PRESSURE SWITCH .............................................................................................46

LOW INLET PRESSURE SWITCH ...................................................................................................46

HIGH OUTLET PRESSURE SWITCH ...............................................................................................46

AIR SWITCH ..................................................................................................................................47

AIR FILTER BOX SWITCH IF EQUIPPED .....................................................................................47

TEMPERATURE LIMITS ..............................................................................................................47

HIGH/LOW GAS PRESSURE SWITCH ...........................................................................................47

Troubleshooting ...................................................................................................4-7

Warranty & Parts 5-1

Standard Warranty for Fulton Thermal Fluid Heaters .......................................... 5-3

Parts ..................................................................................................................... 5-4

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Page 5

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

1-1

Page 6

INTRODUCTION Product-IOM-2011-0216 SECTION 1

Overview

Prior to shipment, the following inspections and tests are made to ensure the highest standards of manufacturing for our customers:

§ Material inspections

§ Manufacturing process inspections

§ American Society of Mechanical Engineers (ASME)

welding inspection

§ ASME hydrostatic test inspection

§ Electrical components inspection

§ Operating test

§ Final engineering inspection

§ Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton equipment, and should be read in its entirety and be made permanently available to the sta responsible for the operation of the heater. It should not, however, be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained, quali ed installers and service personnel. Trained personnel are responsible

for the installation, operation, and maintenance of this product, and for the safety assurance of installation, operation, and maintenance processes. Do not install, operate, service or repair any component of this equipment unless you are quali ed and fully understand all requirements and procedures. Trained personnel refers to those who have completed Fulton Service School training speci c to this product.

Warnings & Cautions

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.

§ 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 e ectiveness.

All Warnings and Cautions are for reference and guidance purposes, and do not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes or regulations.

Disclaimers and Local Codes

Installation of the equipment shall conform to all the requirements or all national, state and local codes established by the authorities having jurisdiction or, in the absence of such requirements, in the US to the National Fuel Gas Code ANSI Z2231/NFPA 54 latest edition, and the speci c instructions in this manual. Authorities having jurisdiction should be consulted prior to installation.

The boiler heat exchanger is manufactured and stamped in accordance with ASME Boiler and Pressure Vessel Code, Section I or Section VIII, Div. 1.

When working on this equipment, observe all warnings, cautions, and notes in literature, on stickers and labels, and any additional safety precautions that apply. Follow all safety codes and wear appropriate safety protection. Follow all jurisdictional codes and consult any jursidictional authorities prior to installation.

1-2

Page 7

INSTALLATION

INTRODUCTION

INSTALLATION

OPERATION MAINTENANCE WARRANTY & PARTS

3 4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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Page 8

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! 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 certi ed 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.

Ensure all labels on the heater are legible. All connections and safety devices, both mechanical and electrical, must be kept clean, with ease of access for inspection, use and maintenance.

Do not store or use gasoline or other  ammable vapors and liquids or corrosive materials in the vicinity of this or any other appliances.

Placement & Rigging

Proper placement of your Fulton Product (see Figures 1 and 2, and Tables 1 and 2) is essential. Attention paid to the following points will save a great deal

of di culty in the future. Correct placement is the  rst step to trouble-free installation, operation and maintenance.

Adhere to the following for equipment placement and rigging:

1. Consult authorities with jurisdiction over any national or local codes (including but not limited to National Fire Protection Agency (NFPA), American National Standards Institute (ANSI), Underwriters Laboratories (UL), SCA, and ASME, which might be applicable to heater applications before beginning.

2. Make appropriate determinations for placement, based on the following:

§ Check building speci cations and Table 3 for permissible  oor loading.

§ Ensure the equipment is to be placed on a non-combustible level base

with adequate clearances from combustible materials. See Clearances &

Serviceability section.

§ Locate heater as close as possible to the place where the heat will be used

in order to keep pipe work costs to a minimum.

§ Ensure that there is adequate clearance around the unit to provide

access for operators and maintenance personnel to all parts of the equipment. Ensure also that clearance provides for component removal for maintenance. See Clearances & Serviceability section. The equipment should be placed in a suitable heater house or well ventilated separate room through which personnel do not normally pass. The layout should eliminate tra c in potentially hazardous areas. For instance, the service engineer or the operator should not have to pass exposed, hot pipe work to make adjustments to the heater controls.

4 CAUTION

Do not allow weight to bear on equipment components to prevent damage.

2-2

§ Ensure the equipment is to be placed in such a way that the electrical

components are protected from exposure to water or excessive humidity.

3. Determine rigging procedure, based on the following:

§ Units are shipped upright and crated for forklift transport. Once uncrated,

all units can be transported with a forklift.

§ If means of lifting are not available, place rollers beneath the frame of the

equipment for guidance to the position of where it is to be installed.

§ Under no circumstances allow weight to bear on the jacket, control panel,

burner, fuel train or fan housing of any Fulton heater.

4. Install a 4 inch (102 mm) curb completely around the unit. In the event of a large spill, this will help contain the  uid.

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SECTION 2 FTA-IOM-2013-0227 INSTALLATION

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. Place heater with clearances to unprotected combustible materials, including plaster or combustible supports, not less than the following:

§ Heater Front 36” (1m)

§ Heater Sides 18” (0.5 m)

§ Heater Rear 18” (0.5 m)

§ Flue Pipe 18” (0.5 m)

§ Heater top (for burner removal) 36” (1 m)

NOTE: ´ Burners may weigh up to 250 lbs (113 kg) depending on the type and

con guration.

! WARNING

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer

to most current guidelines o ered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

3. Pipes must not be run within 10” (254 mm) of any control cabinets or combustible material.

4. Verify that all clearances are acceptable with the local ordinances.

Environment, Ventilation and Combustion Air Requirements

Ventilation must be su cient 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.

Adhere to the following to meet ventilation and combustion air requirements:

1. Install two fresh air openings, one at a low level, 24” (610 mm) from the

 oor, and one at a higher level on the equipment room wall. This will provide a  ow of air to exhaust the hot air from the equipment room.

2. Ensure the burner has an adequate supply of air. Based on NBIC recommendations, unobstructed air openings must be sized on the basis of 0.5 square inch of free area per 1,000 BTU/hr input maximum fuel input of the combined burners in the equipment room or as speci ed by applicable codes.

Failure to provide required and safe access to the equipment could impede commissioning and maintenance. Service technicians are instructed not to commence commissioning if hazardous conditions exist.

Failure to provide proper minimum clearances between equipment and combustible materials may result in  re.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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Page 10

INSTALLATION FTA-IOM-2013-0227 SECTION 2

Legend

A Top Mounted Burner B Electrical Control Panel C Convection Fins D High Density, High Temperature Insulation

Notes

The top-mounted down  red burner delivers a spinning  ame down the length of the furnace. As the  ame swirls downward in a controlled  ow pattern, the  uid spirals upward in the pressure vessel. Hot gases from the  ame are carried up the outside of the vessel in the secondary  ue passage convection area. Convection  ns welded along the full length of the vessel transmit the remaining heat through the outer side of the  uid vessel and into the  uid. The result is even heating of thermal  uids

for optimal thermal e ciency.

FIGURE 1 COMPONENT VIEW OF THE FTA THERMAL FLUID HEATER

2-4

FIGURE 2  DIMENSIONS REFER TO TABLE 2

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SECTION 2 FTA-IOM-2013-0227 INSTALLATION

TABLE 1  SPECIFICATIONS  VERTICAL TUBELESS THERMAL FLUID HEATER

Model FTA 0200 0380 0520 0690 1050 1740

Heat Output

1000 BTU/HR

1000 KCAL/HR

Thermal Fluid Content

GAL

LITERS

Recommended Flow Rate

GPM

M3/HR

Typical Circulating Pump

Motor

Typical Burner Motor

Fuel Consumption @ Full

Output No.2 Oil

GPH

LITER/HR

Natural Gas

FT3/HR

M3/HR

Notes:

Speci cations and Dimensions are approximate. Consult factory for model speci c electrical requirements. We reserve the

right to change speci cations and/or dimensions without notice.

207

7.5

.33

.248

2.2

8.3

259

7.2

348

144

7.5

.33

.248

3.2

11.9

435

12.2

519

131

170

125

11.2

.33

.248

4.7

17.8

649

18.4

693

175

246

125

11.2

.75

.56

6.7

25.4

866

24.2

1052

265

371

150

11.2

.75

.56

9.4

35.6

1315

36.8

1736

437

117

443

200

14.9

1.5

1.1

15.8

2170

60.8

TABLE 2  DIMENSIONSVERTICAL TUBELESS THERMAL FLUID HEATER SEE FIGURE 2

Model FTA 0200 0380 0520 0690 1050 1740

Heater Inlet/ Outlet Connections

(A) Overall Height

(B) Overall Width

(D) Flue Outlet Diameter

Approximate Dry Weight

1.5

1752

737

1092

152

1850

840

1.5

1905

787

45.5

1156

152

2,100

955

2159

838

1168

203

2300

1045

2185

965

1432

254

3400

1540

2185

1168

1626

305

4400

1995

2.5

110

2794

1168

1626

305

7200

3275

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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Page 12

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! WARNING

A quali ed installer, service agency or the gas supplier must perform installation and service on the fuel delivery system.

Do not use matches, candles,  ame or other sources of ignition to check for gas leaks.

What to do if you smell gas: Do not try to light the appliance. Do not touch any electrical switch. Do not use any phone in the building. Leave building and contact gas supplier from neighbor’s phone. If you cannot reach gas supplier, phone the  re department.

TABLE 3 APPROXIMATE FLOOR LOADING*

Model Free Standing Skid Mounted

FT-0200-A 400 250

FT-0380-A 400 250

FT-0520-A 400 200

FT-0690-A 400 250

FT-1050-A 400 300

FT-1740-A 600 400

*All weights are lbs/ft2

3. Ensure the equipment room air supply openings are kept clear at all times.

4. See Table 4 for minimum make-up air required and the recommended area of each opening for each model.

5. If positive forced ventilation is adopted, ensure that there will be no appreciable pressure variation in the equipment room.

6. Avoid ventilation which creates a negative pressure in the building

as it will seriously a ect combustion and proper operation of the stack. Please note that exhaust fans or similar equipment can create a down draft in the chimney or starve the burner’s air supply. Either case may result in poor combustion or nuisance failures.

When making gas piping joints, maintain proper ventilation to reduce breathing hazards.

An exhaust fan may draw products of combustion into the work environment creating a possible hazard to personnel.

4 CAUTION

It is essential that only fresh air be allowed to enter the combustion air system. Foreign substances, such as combustible volatiles and lint in the combustion system can create hazardous conditions. If foreign substances can enter the air stream, the combustion air inlet must be piped to an outside location. Failure to do so will void the warranty.

To avoid failures due to poor combustion, ensure make-up air system is properly designed.

Some soap used for leak testing is corrosive to certain types of metals. Clean all piping thoroughly after completing the leak check.

TABLE 4  MINIMUM MAKEUP AIR REQUIREMENTS AND RECOMMENDED AREA OF

OPENING FOR VENTS

Model Minimum Make-

Up Air (SCFM)*

FT-0200-A 50 115 40

FT-0380-A 95 195 65

FT-0520-A 130 290 100

FT-0690-A 175 385 130

FT-1050-A 265 585 195

FT-1740-A 435 965 325

*Minimum make-up air requirements are based on 25% excess air at high  re.

**Opening areas are calculated based input of a single heater and do not account for the

ventilation needs of the equipment room. These measurements are subject to state and local

regulations.

Opening Area

(in2) Lower

Vent**

Opening Area

(in2) Upper Vent

NOTE: ´ A properly designed make-up air system in the equipment room will

preclude these possibilities and is required to maintain proper combustion.

7. Eliminate potential for high risk situations for particulate matter to be in the combustion air supply (e.g., as a result of construction and maintenance activities).

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Page 13

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

Utilities

¡ The Gas Supply

Adhere to the following for gas supply (Figure 3) installation:

1. Install gas piping in accordance with all applicable codes.

2. Ensure pipe and  ttings used are new and free of dirt or other deposits.

3. Ensure piping is of the proper size for adequate gas supply to the gas head assembly. Consult your gas company for speci c recommendations.

4. When making gas piping joints, use a sealing compound resistant to the action of lique ed petroleum gases. Do not use Te on tape on gas line piping.

5. Ensure no piping stresses are transmitted to the equipment. The equipment shall not be used as a pipe anchor.

NOTE: ´ Even when the unit is shut down, the gas supply

pressure must never exceed these values.

NOTE: ´ When operating, the supply pressure must not drop

below these limits: Not less than 11 “ w.c. where 14” w.c is required. Not less than 50” w.c. where 60” w.c. is required. Not less than 100” w.c. where 120” w.c. is required.

11. After gas piping is completed and before wiring installation is started, carefully check all piping connections, (factory and  eld), for gas leaks. Use a soap and water solution.

¡ The Oil Supply

Fuel Oil Viscosity Speci c

Gravity

#2 Less

than 31.9 Seconds Redwood

#1 at 100 F (38 C)

0.824 to 0.852 at 59 F (15 C)

Sulfur Content

Less than 0.40% by weight

6. Ensure all vent connections on diaphragms, gas valves, pressure regulators, and pressure switches (gas- red units) are vented per local code.

7. On gas- red units with NFPA valve trains, ensure the vent valve is piped to atmosphere per local code.

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 shuto valve (located at the end of the supplied gas train) from the gas supply piping system.

9. Ensure the supply pressure is regulated by a nonstacking, tight, shut-o regulator.

10. Arrange gas piping so that it does not interfere with any cover or burner, inhibit service or maintenance, or prevent access between unit and walls or another unit.The burner assembly and gas controls terminate at a manual stop valve to which the gas supply should be connected. Piping must be sized for a gas  ow consistent with the required BTU/Hr input. Large pressure drops must be avoided. Fulton recommends that the supply piping between the pressure regulator and the inlet to the heater be kept to a minimum. The minimum required gas pressure at the stop valve varies with the model of heater. The requirements for FT-A natural gas- red models are 7 to 11 in. w.c.

Adhere to the following for installation:

1. Fuel pipes must be of approved materials and of a diameter suitable for the quantity of oil being delivered to the burner and the static head available. See Figure

2. Make fuel connection in accordance with the details on the enclosed fuel pump cut sheet.

3. Ensure fuel oil piping is in accordance with local/ national requirements. In addition, if a two pipe system is employed, a check valve must be  tted into the return pipe.

4. Meet the maximum pressure allowed at the fuel oil pump inlet per the National Fire Protection Association (NFPA).

NOTE: ´ If for some reason the pressure of the fuel supply will

exceed NFPA maximum,  tting a regulator to the fuel line must be considered, e.g. when there is a tank situated with an oil level eight feet (2.4 m) or more above the pump.

5. On units  tted with NFPA 85 controls, ignition is obtained by means of a gas pilot. A natural gas or LP supply is required for these units. The required gas supply pressure is 7” w.c. If a guaranteed supply of natural gas is not available, then a supply of bottled

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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Page 14

INSTALLATION FTA-IOM-2013-0227 SECTION 2

1” Gas Connection

Manual Gas Valve

Gas Pressure Regulator

Diaphragm Gas Valves

Butterfly Valve

Pilot Gas Valve

Pilot Gas Regulator

Manual Ball Valve

FIGURE 3  TYPICAL GASFIRED MODULATED CSD1 FUEL TRAIN

gas at 11“w.c. is required. For details contact a local liquid propane dealer.

Instrument Air

Instrument air provision for pneumatically actuated control devices should meet the minimum and

maximum  ow rate and delivery pressures speci ed by the individual equipment. Additionally, it should be a dry, dust free supply with a dew point of -40 F (-40 C).

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  tted by the client/contractor if disconnect is not supplied on the panel.

3. Size fuses according to motor name plates and local electrical codes.

4. Connect power to the terminal strip as supplied on the inside of the panel box.

NOTE: ´ Single skid systems are generally shipped completely

prewired.

NOTE: ´ The liquid level switch on the expansion tank, when

supplied, will be shipped in the parts box and must be

installed in the  eld.

5. Determine multiple skid systems wiring requirements (between the skids). Fulton will run conduit and wire the devices on each skid. For the devices that have to come down for shipping, the wire will be left at the end of the conduit where possible and wired in the  eld (by others). When the system has multiple skids that are adjoining, the conduit will be installed to break at the skid joints. The wire for the conduit running between the skids will be shipped loose to prevent damage when the skids are put back together. These wires will need to be run by the installing contractor in the  eld and wired to proper locations. If there is wiring between skids that are not adjoining, then this will need to be done by quali ed personnel.

2-8

Page 15

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

0-400 PSIG

TO LOW PRESSURE OIL

SWITCH ON CONTROL PANEL

RETURN TO TANK

PUMP INLET

BURNER

3/8" COPPER TUBING

OIL S.S.O.V.

MOUNTED

TO SKID

MOUNTED TO TOP OF UNIT

1/4" COPPER TUBING

SUPPLY

NC OIL VALVE

PRESSURE INDICATOR

FUEL

OIL PUMP

INLET

RETURN

3/8" COPPER TUBING

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

FIGURE 4  TYPICAL NO. 2 OIL FIRED FUEL TRAIN

2-9

Page 16

INSTALLATION FTA-IOM-2013-0227 SECTION 2

NOTE: ´ If the unit is not skid-mounted at the factory, the client/contractor is

! WARNING

required to wire the circulating / feed water pump starter.

NOTE: ´ If the circulating pump motor is not supplied by Fulton, the motor starter

will not be supplied.

6. Locate electrical schematic diagram, a copy of which is inside of the panel box.

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 Z2231-1991 or latest addenda. In Canada, gas installations must be in accordance with the current CAN/CGA B149.1 and 2 and/or local codes.

Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the equipment.

7. Ensure the information on the electrical drawing corresponds to your voltage and frequency.

8. Adhere to the following:

§ Typical 120 VAC controls allow for a +10% and -15% voltage  uctuation.

§ Motors are designed to operate within the following limits at the motor

terminals: AC power supplied is within +/- 10% of the motor rated voltage with the rated frequency applied; or AC power supplied is within +/- 5% of the rated frequency and with the rated voltage; or a combined variation in voltage and frequency of +/- 10% (sum of absolute values) of rated values provided the frequency variation does not exceed +/-5% of rated frequency.

§ 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. Operation outside of these limits will degrade motor performance. 575V rated motors cannot be operated at voltages above 600V. Depending on the motor manufacturer, a 208V rated motor may not be able to run below the design voltage.

Thermal Fluids

2-10

¡ Thermal Fluids at Elevated Temperatures

Personnel must be familiar with the nature of potential hazards when working with thermal  uids at operating temperatures. Unlike steam or high-pressure water systems, thermal  uid attains extremely high temperatures without a corresponding increase in pressure.

Adhere to the following:

1. Be aware that certain types of thermal  uid may have operating temperatures reaching 600 F (316 C) and above, so all exposed pipework is hazardous and should be insulated.

2. Check that  anged joints are tight during and after the  rst warming up of the system. Turn Burner and pump o before  ttings are tightened. After these checks, exposed hot  anges, pumps, valves and  ttings should be  tted with some sort of shield.

3. Remember that there is pressure generated in the system by the circulating pump. Care should be exercised when opening any drain or vent valves in

Page 17

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

the system. This is especially important during commissioning, when any air trapped in the system is vented at high points, and when water, which

will  ash into steam, is either expelled from the deaerator vent or drained

o at low points.

¡ Selecting a Thermal Fluid

The selection of the thermal  uid most suited to your application is very

important. Factors to be considered include e ciency, thermal stability, adaptability to various systems, and physical properties, including vapor

pressure, freezing point, and  ash and  re points.

Heat transfer  uids of both mineral and synthetic origin have been specially developed to give thermal stability over a very wide range of temperature. A wide variety of thermal  uids have been used successfully in Fulton Thermal Fluid Heater systems, however, your  nal selection should be made in conjunction with recommendations from Fulton Thermal Corporation or the  uid manufacturer.

Consider the following for selection:

1. The Fulton vertical tubeless thermal  uid heater is a  red heat exchanger and the safe control and monitoring of the thermal  uid temperature is of paramount importance.

! WARNING

4 CAUTION

Proper selection of thermal  uid is critical to system performance.

2. The safe maximum bulk temperature of the  uid must be strictly adhered to. The safe maximum temperature of the  uid varies.

3. Special care must be taken when consulting  uid manufacturers’ literature, as maximum  uid temperatures quoted are the actual limit to which any of the  uids may be subjected. It is important to remember that in any  red heater there exists a “ lm temperature” which is higher than the temperature of the “bulk” of the  uid. It is the BULK  uid temperature and NOT the FILM temperature that is indicated by the instruments.

4. As a general guide, the following list of  uids that have given satisfactory service over many years is provided. This is by no means a complete list. Any  uid speci cally designed for heat transfer use may be considered; multipurpose oils are not acceptable.

§ AMOCO Transfer Oil 4199

§ CHEVRON

§ DOW G

§ EXXON 43

§ MOBIL

§ MONSANTO

§ MULTITHERM

§ PARATHERM

§ PETROCANADA T

§ SHELL

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-11

Page 18

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! WARNING

If a  re does occur, extinguish using CO2 foam or dry chemical. DO NOT USE WATER.

4 CAUTION

Some plastics can be dissolved by

thermal  uid.

If excessive amounts of thermal  uid are vented from the system, additional thermal  uid may be required in the system. Contact Fulton for further information.

§ TEXACO

5. Any  uid speci cally designed for heat transfer use must also exhibit these

characteristics:

§ Be a stable and homogenous liquid to a temperature of at least

100 F (38 C) over and above the maximum intended temperature of utilization, compatible with metals used in the installation, and tolerating contact with atmospheric air.

§ No solid matter in suspension.

§ Non-toxic in the case of leakage.

§ Su cient lubricity, i.e. not likely to cause seizure.

6. The thermal  uid manufacturer must guarantee the characteristics of the product, and verify that the  uid bulk temperature limitation exceeds the expected operating temperature

7. After a  uid is selected, refer to the manufacturer’s recommendations, published in compliance with the Occupational Safety and Health Administration (OSHA).

8. If the  uid expansion volume from 50 F to 600 F (10 C to 316 C) exceeds 20% of the initial  uid volume, consult Fulton Thermal Corporation.

¡ Routine Analysis of Heat Transfer Fluid

Nearly all leading manufacturers of heat transfer  uids provide an after sales service to monitor the condition of the  uid in operation and make recommendations when replacement becomes necessary.

Each  uid manufacturer has procedures for regular testing and analysis of the  uid. These usually allow for a sample to be taken and analyzed at least once a year, although actual frequency will depend on operating temperature, number of hours operated weekly, and the results of tests made during the  rst weeks of system operation.

Fulton Thermal Corporation recommends that the thermal  uid in your system be analyzed within the  rst two months after startup and annually thereafter.

During the  rst few months of operation, sampling may be carried out at frequent intervals to con rm that system performance has been predicted correctly.

If the supplier of your thermal  uid does not contact you within four weeks of commissioning, contact the supplier and make certain that the “ ll” is registered for routine analysis.

¡ Thermal Fluid Breakdown

The possibilities of thermal  uid breakdown are very slim in a typical closed loop

thermal  uid system. Fulton’s combination expansion/deaerator/thermal bu er tank creates a “cold seal” of  uid that is slightly above ambient temperature. This prevents oxidation that will otherwise happen when high temperature  uid

2-12

Page 19

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

contacts air.

Oxidation of the  uid will also occur when hot thermal  uid contacts air at a leak in the system piping. Oxidized thermal  uid becomes acidic and will damage the thermal  uid system. Thermal  uid breakdown can occur in sections of piping where there is a low  ow condition. A low  ow rate through the heater will result in high  lm temperatures leading to breakdown of the thermal  uid.

} THERMAL FLUID BREAKDOWN PREVENTION

§ Multiple pressure switches and a di erential pressure switch are used to

prevent this condition from occurring. See Figure 5. These safeties must not be bypassed at any time.

§ Exceeding the maximum operating temperature of the thermal  uid will

also result in thermal  uid breakdown. Fulton heaters are equipped with a temperature limit switch (located on the front of the panel box) to prevent this from occurring.

§ 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  ame programmer must also be pressed to reset the unit before it can be restarted. See Figure 6. Refer to Maintenance section of this manual for troubleshooting activities.

! WARNING

FIGURE 5  PRESSURE SWITCHES

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-13

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INSTALLATION FTA-IOM-2013-0227 SECTION 2

! 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.

Piping Speciﬁ cations

For piping, the basic considerations are: the design temperature, the pressure

retained by the pipe, the  uid in the pipe, the load resulting from thermal expansion or contraction, impact or shock loads imparted such as water hammer, external loads, wind loads and vibration from equipment.

FIGURE 6  TEMPERATURE LIMIT DISPLAY

Adhere to the following for piping installation (see Figure 7):

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. Valves are used in piping systems to stop and start the  ow of  uids, to regulate  ow, to prevent the back  ow, and to relieve excessive pressure build up in the piping.

3. Ensure all piping and piping components are suitable for the design temperatures, pressure and  uid used in the system.

4. Ensure all components exposed to thermal  uid  ow, including pipe, valves, and screens, are not copper, copper alloys, bronze, brass, aluminum, or cast iron. Cast iron is porous to thermal  uids, and copper and aluminum act as catalysts in the degradation of some thermal  uids. Carbon or stainless steel, or ductile iron, are recommended.

5. Ensure all pipework is constructed from seamless mild steel pipe, conforming to ASME SA 106B or SA 53B, Schedule 40, Schedule 80, or equal, based on design temperature and pressure of the system.

2-14

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. Where secondary circulating pumps are installed, ensure the system is

Page 21

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

suitable for the aggregate head, against a closed valve, of both pumps.

8. During construction of the installation, ensure that no dirt, water, or residue from welding is left in the system.

9. Consider expansion joints or pipe loops to accommodate thermal expansion. Design should be per latest edition of ASHRAE Systems and Equipment Handbook to prevent detrimental forces and stresses at connected equipment. Thermal expansion should be calculated using the

maximum possible utilization  uid temperature, regardless of whether the pipe considered is in the feed or return circuit. Steel pipe will grow axially and can be expected to expand approximately 1” over 100ft @ 100dg F temperature rise (1mm per meter over 100 C rise).

10. Provide properly designed supports and anchors for all piping where necessary to prevent undue stress from being imparted on equipment such as pumps, valves and the heater. Care should be taken as end reactions transmitted to rotating equipment, such as pumps, may deform the equipment. Therefore equipment manufacturers’ recommendations on allowable forces and movements should be followed. See Figure 8.

11. Ensure all pipe joints are of either welded or  anged construction. Screwed joints must be avoided where possible. In no instance should screwed joints be used in the  ow circuit. All  anges should be welded to the pipe

and not screwed. Depending on the size,  anges should be 150# or 300# raised face  anges, SA105.

12. Ensure heaters that are skid mounted with pumps and tanks are equipped with a y-strainer, a  ex connector and a valve in the inlet run between the pump and the combination tank. Piping between the discharge of the pump and the inlet of the heater will include a  ex connector and a valve.

! WARNING

4 CAUTION

The weight of all piping must be properly supported. Failure to support piping may result in equipment damage and/or system leakage.

Piping must take into consideration potential for damage as a result of expansion, contraction, vibration, or other movements.

Dirt, water, and/or other debris in the piping system after welding may result in equipment failure.

13. If screwed connections have to be made, e.g., to items of control equipment, use a thread sealant suitable for use with  uids at elevated temperature. Te on tape, standard pipe sealant, or hemp and paste are not acceptable.

14. Cut screw threads carefully and accurately. If possible, 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  anged joints.

15. Use gaskets to make all  anged connections. Gasketing material must be suitable for use with the pressure, temperatures and  uids in the system. Flexible graphite gaskets are suited for most applications. Recommended gasket thickness is 1/10 - 1/8 inch. Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer. Refer to Figure 9 and Tables 5-8 for guidelines.

NOTE: ´ Typical gaskets used by Fulton include JM Clipper Elastograph gaskets and

Flexitallic gaskets. Adhere to installation instructions and torque requirements for these gaskets.

16. Install high point bleeds at all high points in the system piping. 1/2” x 12”

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-15

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INSTALLATION FTA-IOM-2013-0227 SECTION 2

nipples welded in the top of the piping with ball valves and plugs attached are to be used.

NOTE: ´ It will save a considerable amount of time during the

cold  ltration if the system piping is cleaned prior to assembly. The mill scale (the results of oxidation) on the inside of the

piping as well as construction debris can foul the  uid and

cause the need for the  lters (strainers) to be cleaned more than need be. This can range from simply using a rag to ordering pickled pipe. (“Pickling” is a process where the piping is  rst soaked in an acid bath, then soaked in a neutralizing bath, then given a protective oil coating.)

17. Install all pipes with a pitch to facilitate draining and venting.

Legend

1. Thermal Fluid Heater

2. Thermal Fluid Circulating Pump

3. Safety Relief Valve

4. Thermometer

5. Pressure Gauge

6. Thermal Fluid Heated Equipment

7. Bypass Valve

8. Expansion Joints

9. Anchor and Pipe Guides

10. Expansion Tank

11. Vent Piping

12. Deaerator Tank

13. Deaerator Tank Inlet (must be highest point of piping)

14. Thermal Bu er Tank

15. Catch tank (for drain of pressure relief valve, cold seal, expansion tank, vent)

16. Valve

17. Strainer

18. 3/4” System Fill Connection

19. Flexible Connection

2-16

FIGURE 7  TYPICAL THERMAL PIPING SCHEMATIC

Page 23

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

Pump

Pipe Must Be Diameter of Pump Intake

From Outlet of Deaerator

First Fitting

Pipe Support Must Be Provided (Not To Be Welded On Both Ends)

6 - 10 Pipe Diameters

FIGURE 8  TYPICAL PUMP PIPING

FIGURE 9  BOLTING SEQUENCE FOR 4 AND 8 BOLT FLANGES

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-17

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INSTALLATION FTA-IOM-2013-0227 SECTION 2

! 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.

TABLE 5 - RECOMMENDED GASKET LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 150#

GASKETS SAE GRADE 5 BOLTS OR EQUAL

Nominal Flange

Size (in.)

1/2 4 1/2 45

3/4 4 1/2 45

1 4 1/2 45

1 1/4 4 1/2 45

1 1/2 4 1/2 45

2 4 5/8 90

2 1/2 4 5/8 90

3 4 5/8 90

3 1/2 8 5/8 90

4 8 5/8 90

5 8 3/4 150

6 8 3/4 150

8 8 3/4 150

10 12 7/8 240

Number of Bolts Diameter of Bolts

(in.)

Preferred Torque

Req. Per Bolt (ft-lb)

TABLE 6 - RECOMMENDED LOADS FOR FLEXITALLIC SPIRAL WOUND CLASS 300# GASKETS

SAE GRADE 5 BOLTS OR EQUAL

Nominal Flange

Size (in.)

1/2 4 1/2 45

3/4 4 5/8 90

1 4 5/8 90

1 1/4 4 5/8 90

1 1/2 4 3/4 150

2 8 5/8 90

2 1/2 8 3/4 150

3 8 3/4 150

3 1/2 8 3/4 150

4 8 3/4 150

5 8 3/4 150

6 12 3/4 150

8 12 7/8 240

10 16 1 368

Number of Bolts Diameter of Bolts

(in.)

Preferred Torque

Req. Per Bolt (ft-lb)

2-18

Page 25

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

TABLE 7 - RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH 150# GASKETS SAE

GRADE 5 BOLTS OR EQUAL

Nominal Flange

Size (in.)

1/2 4 1/2 30

3/4 4 1/2 30

1 4 1/2 30

1 1/4 4 1/2 30

1 1/2 4 1/2 30

2 4 5/8 60

2 1/2 4 5/8 60

3 4 5/8 60

4 8 5/8 60

5 8 3/4 100

6 8 3/4 100

8 8 3/4 100

10 12 7/8 160

TABLE 8 - RECOMMENDED LOADS FOR JM CLIPPER ELASTOGRAPH 300# GASKETS SAE

Number of Bolts Diameter of Bolts

(in.)

GRADE 5 BOLTS OR EQUAL

Preferred Torque

Req. Per Bolt (ft-lb)

! 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.

Nominal Flange

Size (in.)

1/2 4 1/2 30

3/4 4 5/8 60

1 4 5/8 60

1 1/4 4 5/8 60

1 1/2 4 3/4 100

2 8 5/8 60

2 1/2 8 3/4 100

3 8 3/4 100

4 8 3/4 100

5 8 3/4 100

6 12 3/4 160

8 12 7/8 245

10 16 1 160

Number of Bolts Diameter of Bolts

(in.)

Preferred Torque

Req. Per Bolt (ft-lb)

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-19

Page 26

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! 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.

To maintain a reasonable temperature in the equipment area and ensure safety to personnel, the section of the chimney duct within the building should be insulated.

Due to extremely high operating

temperatures of the thermal  uid, all exposed pipework should be insulated, and exposed hot  anges, pump, valve, and  ttings should be shielded. Refer to Insulation section of this manual for details.

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,  anges, valves

and  ttings uninsulated but suitably shielded for safety.

2. Insulate the deaerator section of the combination tank.

3. Do not insulate the thermal bu er and expansion sections of the combination tank. On units operated with inert gas blankets above the  uid in the expansion tank, the entire combination tank, including the expansion and thermal bu er sections, may be insulated but it is not necessary.

4. Ensure hot oil pipe insulation is a minimum of 2” (51 mm) thick, high temperature, laminated, foamglass cellular glass insulation as manufactured by Pittsburgh Corning Corporation or equal.

System Interfaces

Proper selection and installation of the components in the hot oil system will ensure proper and safe operation of the heater.

¡ Heater Connections

Adhere to the following for heater connections:

1. Connect the outlet of the pump directly to the inlet of the heater via an isolating valve (preferably a throttling valve) and pump  exible connector.

2. Pipe heater outlets directly to the system via an isolating valve.

3. A safety relief valve may be shipped in the parts box accompanying the fuel- red 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  ow 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. If the valve body becomes warped, leakage may result.

¡ Thermal Fluid Circulating Pump

Installing the pump in accordance with the manufacturer’s speci cations and these instructions will prolong the life of the pump and contribute signi cantly to the successful operation of your Fulton heater system. The

2-20

Page 27

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

pump manufacturer’s installation and operation instructions can be obtained from the manufacturer.

Adhere to the following for pump installation:

1. Locate pump adjacent to the heater. Its base must be  rm, level (preferably concrete), and free from vibration.

2. Route pump per the manufacturer’s requirements. It should be equipped with  exible connections at the suction and discharge sides. The primary function of these connections are to prevent stresses due to pipe expansion from being placed on the pump and to isolate pump vibrations from the pipe work and the heater. They also allow for expansion and de ection of the pipe work. These connections should be rated for high temperature since they are considered part of the piping system.

3. Connect suction pipe work directly to the deaerator section via a vertical run with as few elbows as possible. It should contain the strainer and an isolating valve. The discharge pipe work must be connected directly to the heater inlet, and should contain an isolating valve. See that pipe work connections match up accurately with pump  anges. Refer to the pump manufacturer’s recommendations for the speci c pump inlet piping requirements. Typically these requirements are that:

§ It be a straight run of pipe.

! WARNING

No shuto of any kind may be placed between the safety relief valve and the equipment, or in the discharge pipe between such valve and the atmosphere. Doing so may cause accidental explosion from overpressure.

Discharge from safety relief valve must be con gured so that there is no danger of scalding personnel or causing equipment damage. Provisions must be made to properly drain safety relief valve discharge piping.

§ The straight run from the pump inlet to the  rst  tting, valve, or  ex

connector be a minimum of 6-10 pipe diameters in length.

§ The pipe used should be the same size as the inlet of the pump.

§ The piping in the immediate vicinity of the pump must not be supported

by the pump. The pump is not designed to bear the weight of the piping, and weight on any part of the pump will throw it out of alignment.

§ Proper alignment directly a ects bearing, coupling, and seal life

expectancy. The pump is properly aligned before it leaves the factory. Because the system expands in operation, pump must be realigned when the system is at operating temperature.

§ The coupling alignment of the pump and driver must be carefully

checked for angular and axial alignment. Check pump manufacturers instructions for these speci cations. 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  uid. 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.

§ An oiler is shipped with each water cooled pump and should be  lled

with lubricating oil recommended by the manufacturer. The suggested lubricant is usually a SAE-30 non-detergent oil.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-21

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INSTALLATION FTA-IOM-2013-0227 SECTION 2

§ Thermal  uid is not su cient lubrication for bearings.

§ All seals on air cooled pumps are lubricated by thermal

 uid, therefore the pump must never be run dry, i.e., without thermal  uid in it.

§ Filling a pump equipped with either a Grafoil packed

or mechanical seal with thermal  uid will ensure lubrication. However, in order to be certain that all seals on an air cooled pump are coated with thermal  uid, the pump must be bled.

§ Grafoil packings require a run-in procedure. Typically,

pumps with these seals are shipped with four or  ve rings installed and several rings loose. These extra rings must be on hand for the initial run-in procedure. See manufacturer’s instruction manual for this procedure.

¡ Requirements for Air Cooled Pumps

Adhere to the following for air cooled pumps (See Figure 10):

1. Allow for free air  ow around the entire pump casing at

all times.

2. Maximum room temperature should be 100 F (38 C).

¡ Requirements for Water Cooled Pumps

Adhere to the following for water cooled pumps (See Figure

11):

1. Requirements for water cooled pumps will vary with manufacturer. Consult manufacturer’s instructions for  ow rate and temperature requirements.

2. Check local codes regarding disposal of hot water.

¡ Combination Deaerator/Thermal Buﬀ er/

Expansion Tank

Fulton Thermal’s e cient design combines the operation of the expansion, deaerator, and thermal bu er tanks.

Installation is considerably simpli ed by virtue of this arrangement. See Figures 12 and 13.

The expansion section is vital to the thermal  uid system. From ambient to operating temperature, the thermal  uid in the system will typically expand in the range of 25% to 50%, and a vessel capable of handling this expansion is mandatory.

The customer should con rm the expansion rate of the

chosen  uid and system volume.

3. In no case should any part of the drive side of the pump be insulated.

4. Maximum operating temperature for air cooled pumps varies by manufacturer. Consult instruction manual to verify.

At start up, the primary purpose of the deaerator section is to remove all volatiles from the system to avoid pump cavitation. The deaerator section also allows air to be vented from the system on a continuous basis during operation to avoid oxidation of the thermal  uid, and removes other volatile particles generated by the  uid itself during system

2-22

FIGURE 10  TYPICAL AIR COOLED PUMP

Page 29

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

operation. This section of the tank must be insulated.

A system of interconnecting pipe work in the thermal bu er tank section prevents the movement of any oil that has not

cooled su ciently into the expansion section. This avoids contact of very high thermal  uid temperature with oxygen contained in the atmosphere, which causes  uid breakdown. DO NOT insulate this section.

¡ Sizing The Expansion 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 top of the tank to avoid spillage or over ow. At initial  ll (for system volume calculations) the deaerator and cold seal sections must be  lled completely and the expansion section must be  lled to a level of 4 inches (102 mm) to “make” the liquid level switch.

The volume between the initial  ll 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.

} SIZING EXAMPLE

Adhere to the following for installation:

1. Install tank in accordance with Fulton Thermal Corporation’s speci cations.

2. Unless the system is pressurized, the inlet to the deaerator section must be higher than or equal to the highest point in the system to prevent pockets of air from collecting in system piping.

3. Take into account the head required at the circulation pump suction inlet to avoid the possibility of pump cavitation.

4. In systems operating close to maximum  uid temperature, ensure the tank is elevated enough, possibly well above the highest point in the system, to prevent pump cavitation by increasing the static head. An inert pressurizing blanket may be considered as an alternative. See Pressurized Systems section of this manual.

5. Provide supports for tank mounting. These should be suited for supporting the tank by the side rails. The eyelets  tted to the tank are for lifting only.

A system contains 175 gallons, including the heater, but not the tank. You select the FT-200-L, so you add 25 gallons to 175 for a total of 200 gallons.

You look up the expansion rate for the thermal  uid. (Assuming it is 25%), 200 gal. x 1.25 = 250 gallons, 250-200 = 50 gallon expansion.

The FT-200-L has only 46 gallons available for expansion, so the correct selection is the FT-500-L.

¡ 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  uid 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  uid from oxidation.

In conjunction with this system, adhere to the following:

FIGURE 11  TYPICAL WATER COOLED PUMP

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-23

Page 30

INSTALLATION FTA-IOM-2013-0227 SECTION 2

Hot Fluid

Medium Fluid

Cool Fluid

Gases (Steam)

Fluid In

Liquid

Level

Switch

Fluid Out Drain

Vent for Piping

to Safe Catchment

Expansion

Tank

Deaerator

Section

Thermal

Buer Section

Expansion

Volume

! WARNING

4 CAUTION

If the deaerator/thermal bu er/ expansion tank is located outdoors, a nitrogen blanket is required.

1. An automatic venting device must be  tted to the system expansion tank. Consult Fulton Thermal Corporation for further details.

2. The location for the liquid level switch (Figure 14) is a 2-1/2” NPT connection on the same end of the tank as the inlet. The liquid level switch is supplied and shipped with the unit, and must be installed by the customer and then wired to the control panel.

3. If the tank is located outdoors, nitrogen is required.

2-24

Model Capacity

(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

FIGURE 12 - EXPANSION TANK DETAILS

Initial Fill

(gallons)

Available for

Expansion

(gallons)

Max System

Volume

Page 31

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

(50.8)

1/2C

(76)

N2 REGULATOR

CONNECTION

TEST

MANUAL

LEVEL

LIQUID

DRAIN & LIQUID LEVEL

(13)

1/2

DRAIN

G H

OUTLET

INLET

COUPLING

SWITCH

LIQUID LEVEL

BUFFER

THERMAL

DEAERATOR

EXPANSION TANK

(13)

1/2

(TYP.)

VENT

VALVE CONN.

SAFETY RELIEF

Model A B C D E F G H J K L M N P CAP Dry

Wt.

FT-

0200-L

FT-

0500-L

FT-

1000-L

FT-

1500-L

FT-

2000-L

FT-

3000-L

FT-

5000-L

Inlet and outlet dimensions vary with installation. All dimensions are approximate. Speci cations are subject to change without notice. Dimensions

(510)

(660)

(915)

(1070)

(1524)

12 3/4

(325)

(1370)

(405)

(1880)

(510)

(1930)

106

(510)

(2690)

106

(560)

(2690)

140

(660)

(3556)

130 3/8

(3312)

60 5/8

(1540)

66 5/8

(1692)

87 5/8

(2226)

(2210)

107 5/8

(2734)

115 1/8

(2924)

132 1/8

(3356)

(865)

(940)

(1245)

62 1/2

(1590)

(1778)

77 1/2

(1969)

26 5/8

(676)

29 5/8

(752)

38 5/8

(981)

38 5/8

(981)

45 1/8

(1146)

45 1/8

(1146)

54 5/8

(1387)

16 11/16

(424)

19 3/4

(502)

22 1/4

(565)

24 3/4

(629)

31 3/16

(792)

33 3/16

(843)

32 3/16

(818)

(305)

(355)

(380)

17 1/2

(445)

(610)

4 1/2

4 1/4

(115)

(108)

6 (150) 11 1/2

(290)

7 11/16

14 (355) 24

(202)

8 (203) 14 (355) 24

8 1/2

15 1/2

(216)

(394)

9 15/16

15 1/2

(252)

(394)

9 3/8

20 5/8

(238)

(524)

(380)

(460)

(610)

(710)

(940)

12 15/16

(329)

14 15/16

(379)

14 15/16

(379)1 (25)

14 15/16

(379)1 (25)

14 15/16

(379)1 (25)

18 15/16

(481)1 (25)

18 15/16

(481)1(25)

3/4

(20)

3/4

(20)

3/4

(20)

3/4

(20)

(25)

1 1/4

(32)

1 1/2

(38)

1 1/2

(38)

1 1/2

(38)

(200)

132

(500)

264

(1000)

397

(1500)

528

(2000)

793

(3000)

1321

(5000)

636

(289)

970

(440)

1350

(612)

1710

(776)

2550

(1134)

3200

(1451)

5300

(1637)

are in inches (mm). Capacities are in gallons (liters). Weights are in pounds (kg).

FIGURE 13  COMBINATION/EXPANSION/DEAERATOR THERMAL BUFFER TANK

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

Max

Full

Wt.

1314

(596)

2450

(1111)

4380

(1987)

5875

(2667)

8230

(3733)

11,610

(5265)

17,370

(7895)

2-25

Page 32

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! WARNING

High temperature thermal  uid, steam, and combustible vapors may be vented through the vent connection on the combination

deaerator/thermal bu er/expansion tank.

4 CAUTION

Non-code tanks cannot be pressurized over 15 psig.

FIGURE 14  LIQUID LEVEL SWITCH LOCATION

¡ Vent Connections

Adhere to the following for vent connections:

1. Make vent connection 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  uid could drain into a catch tank without danger to personnel or property.

2. Make the vent run the same size as the tank outlet. It should run pitch down from the outlet of the tank to the catch tank.

3. If nitrogen is used on the system, the vent can be reduced to 2” (51 mm) and should be piped with a positive closing valve at the catch tank.

4. Ensure the connection between the tank outlet and the horizontal pump inlet is as close to a vertical drop as possible. It should have the minimum bends and length of pipe.

5. Ensure the inlet to the deaerator is higher than or equal to the highest point in the system, or a pressurized system must be used.

2-26

6. Field-install the liquid level switch (supplied and shipped with the unit). This must be wired to the control panel.

7. Ensure test connections are accurate. The high and low level test

Page 33

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

connections are 1/2” NPT, and are located on the end of the tank opposite

the inlet. The low level is on the center line of the expansion tank, the high

level is next to it, slightly o center. The high level rises up from the bottom of the tank and ends 4” (102 mm) below the top; the low level rises 2” (51 mm) from the bottom of the tank.

8. Both the high and low level connections should be piped to a safe catchment. Valves should be installed in these lines at the catch tank. Installation of the valves should be accomplished in such a manner that any  ow will be visible when the valves are open.

9. Flow from the high level test connection indicates a tank that is too full; no  ow from the low level test connection indicates too little  uid.

10. There is a 300 #, raised face,  anged drain on the bottom of the thermal

bu er section, for the purpose of draining the tank when necessary. This should be piped with a valve in the line, to a safe catchment. The valve speci cations outlined above apply to this valve as well.

11. An inspection opening is located at the highest point on the tank. Access to this port is recommended but not required.

12. Refer to the maintenance schedule for recommendations on draining the bu er tank. For positioning of all connections on tank, see Figure 13.

! WARNING

Failure to ensure vent connections terminate into a well-ventilated area with catch tank may create an environmental hazard.

¡ 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 con guration.

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.

¡ Drain/Fill Connection

The system is usually  lled from the lowest point, with the aid of a pump. On skidmounted units, a drain and  ll connection is provided in the inlet piping to the pump. See Figure 15.

¡ Pressure Gauges

The range in which readings are expected to fall should comprise mid-scale on the pressure gauge chosen (See Figure 16). Pressure gauges must be able to withstand overpressure equal to the rating of the safety relief valves, normally 100 psig.

¡ Thermometers

Thermometers should read up to 650 F (343 C). For systems with higher operating temperatures, thermometers should be selected accordingly.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-27

Page 34

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! WARNING

Once the system has been  lled, any modi cation to the tank or connected piping requires purging of the work area to prevent ignition

of potentially  ammable vapors. Consult factory prior to beginning work. Consult Material Safety Data Sheet (MSDS) for your thermal  uid for  ammability limits.

FIGURE 15  DRAIN AND FILL CONNECTION

2-28

FIGURE 16  GAUGES

¡ Valves

Adhere to the following for valve installation:

1. Use vent and drain valves that normally are 1/2” or 3/4” with internal seals

made from materials suited to use with thermal  uids. They may be of the screw type if installed on stalks not less than 12” (30.5 cm) long.

2. Use gasketing material speci cally suited to the task.

3. Fit drain valves at all low points in the pipework system and ventilating valves at all high points in the installation. Valves must be  tted with either

the conventional packed stu ng box seal or a bellows seal as required.

4. Where the stu ng box is speci ed, it should be as deep as possible and

Page 35

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

packed with Grafoil packing or equal. The valves should have a backseating

to allow re-packing without draining the system.

5. In all units, install a “Y” type strainer in the  uid return line, between the

deaerator tank and the circulating pump. 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. The strainer element should be 60 mesh and must remain in place during normal operation of the system.

6. Check the pump suction pressure periodically, under similar operating conditions. A vacuum reading on the suction gauge indicates that the screen must be cleaned. For isolating purposes, globe, wedge, gate, ball, or

other shut-o valves should be used. When there is a likelihood that some manual balancing will be required, a ball or globe valve should be used.

7. Ensure manual control and isolating valves are of the  anged or weld type, manufactured from cast or forged steel or ductile iron, with internals and gland seals made from materials suitable for use with high temperature  uids.

8. When ordering valves, obtain the maximum possible service temperature and type of  uid. A partial list of manufacturers known to market valves of acceptable quality follows:

! WARNING

§ Stockham Valves and Fittings Company

§ Velan

§ Vogt Machine Company

§ Worcester Valve Company

¡ Automatic Fluid Control Valves

Because of the widely varied processes in which Fulton Thermal Fluid Heaters are used, it is not possible to provide speci c rules for the selection of automatic  uid control valves. Generally, these valves must satisfy the speci c 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.

¡ By-Pass Valves

When process  ow requirements do not match heater  ow requirements, a bypass valve must be installed. If the process  ow will vary with the system load, a suitable bypass system can be recommended by Fulton Thermal Corporation.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-29

Page 36

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! WARNING

Assembly of Fulton Multi-Skid Engineered Systems

Adhere to the following for multi-skid engineered systems:

1. Refer to the Fulton mechanical/electrical drawings during assembly.

2. Ensure that the equipment orientation allows for operation interface and maintenance.

3. Align skids as shown in the drawings, ensuring that the skid fasteners are matched.

4. Ensure the skids are leveled and fasten the skids together using the supplied bolts. The skids should be leveled front to back, side to side and corner to corner. Failure to properly level the skids will result in piping misalignment. A level or laser level should be used to verify skid alignment (when a standard level is used, the length should be appropriate for the skid) If assembling multi-component support stands, attach sections using the supplied bolts through the tank frame mounting plates. These should be hand tight until all piping has been assembled and tightened.

5. Connect the piping between skids by matching the union connections

and/or  ange stamps and tightening. Refer to the appropriate instructions to tighten the  anges and required torque speci cations. Support pipe runs as required.

6. Ensure that a low point drain is installed in the piping.

7. Connect the conduit runs between skids and tighten the conduit connectors.

8. Locate the supplied wiring for the equipment and pull wiring through the appropriate conduit runs. Electrical wires are labeled for easy landing. Connect all wiring per the Fulton supplied electrical drawing.

9. If a header is supplied, mount the header as shown in the mechanical drawing.

NOTE: ´ For piping supplied in sections, make up and connect hand tight until

all sections are in place to ensure sections align properly. Sections are match marked for reassembly.

10. Tighten all connections.

11. Pneumatically test the piping (at 15 psig maximum) prior to  lling the system.

2-30

12. Check bolts and connections for tightness after the  rst heat up cycle. Retorquing may be required.

Page 37

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

! WARNING

Stack and Flue

All information in this manual is for

An appropriately sized stack should be connected to the  ue gas outlet at the heater. The proper  ue size and draft control is most important for proper burner operation. The  ue must be as large or larger than the outlet on the vessel. Avoid  ue piping and elbows by placing the equipment as close as possible to the chimney.

Adhere to the following for stack and  ue installation (see Figure 17):

1. Ensure the stack rises continuously to the connection at the chimney and contains no more than two bends at 45 degree angles or less. If required, as a result of space limitations, one 90 degree elbow (or tee) can be  tted at the back of the vessel.

2. Ensure 2 feet (0.6 m) of straight, horizontal  ue before any change in direction,  tting or draft regulator. This is to prevent potential pilot or main  ame failures due to back pressure build up during ignition. Any alternative stack arrangement must supply negative 0.02 to 0.04”wc.

3. Ensure the run in the total distance of stack ducting, as measured in a straight line from the outlet of the heater to the outlet of the stack, does not exceed 70% of the rise. With the exception of the duct run previously described, horizontal sections of ducting must be avoided and should not exceed 4 feet (1.2 m) total. See Figure 17.

reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional/professional codes and regulations.

For reasons of safety, the hot exhaust gas duct and chimney must be insulated or shielded within the locality of the heater in compliance with local codes and regulations.

4 CAUTION

The stack arrangement and draft conditions should be in accordance with the information in this manual for proper performance of the equipment.

4. Ensure the stack, chimney, and any components associated with the stack, such as heat reclaimers or assist fans, are constructed from material that is rated for a 1200 F (649 C) operating temperature.

5. Ensure the stack and chimney material complies with all applicable codes.

6. 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.

7. Ensure the draft, when  ring, is negative and constant. A reading of -0.02 to

-0.04”wc when the unit and stack are cold usually indicates su cient draft. When the unit is running and the stack is hot, the draft should read 0.04 to

0.08 “wc negative.

8. The installation of a draft regulator by the client/contractor is recommended at all installations. This will help to maintain the required draft. The placement of the draft regulator should be as shown in Figure 18.

9. Insulate the section of the chimney duct within the building.

10. Concentration levels of only a few ppm of chlorine containing compounds

in combustion air can produce serious corrosion of the  ue over long periods of time. High chlorine containing compounds such as carbon tetrachloride or perchloroethylene would be prime suspects.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-31

Page 38

INSTALLATION FTA-IOM-2013-0227 SECTION 2

! WARNING

Testing

Upon completion of the installation, perform the following testing:

1. A pneumatic test of thermal  uid piping not exceeding 15 psig.

2. Soap tests at all welds and joints to ensure that the system is free from leaks.

Do not attempt to start the equipment for any testing prior

to  lling and purging the vessel. A dry  re will seriously damage the equipment and may result in property damage or personnel injury and is not covered by warranty. In

case of a dry  ring event, shut o the fuel supply and allow the vessel to cool to room temperature before  uid is reintroduced to the pressure vessel.

4 CAUTION

Avoid  ue corrosion and other negative impacts ensuring properly-sized stack and  ue.

In order to meet warranty conditions, ensure appropriate tests and operational safety activities are performed.

NOTE: ´ Under no circumstances should the system be  lled with water. Make sure

that the air supply is as free from moisture as possible.

3. Boil-out. The time needed for adequate boilout directly corresponds to the volume of the system and the amount of moisture and debris in the system. Boilout typically takes anywhere from one to three days to complete. Pressure testing on the system should be done by means of an inert gas such as nitrogen or by an air compressor producing dry air (air with a dewpoint of 50 F [10 C] or less). Never perform a hydrostatic test on the system. The boilout procedure is described in the Operation section of this manual.

4. The most satisfactory method of testing is to introduce bottled nitrogen through a pressure control valve. Check pressure ratings on all equipment in the system to ensure that it is capable of withstanding the pressure involved.

Unless specially  ltered, compressed air will introduce moisture to the system. Dry air or nitrogen is recommended.

2-32

Page 39

SECTION 2 FTA-IOM-2013-0227 INSTALLATION

Roof

Minimum

6' Above

Any Structure

Within 30'

Support As

Necessary

Install Appropriate Weather Cap

Horizontal Run 2'

Draft Regulator (If Necessary)

Expansion Joints As Required

Horizontal Run 2'

60°

(45° Min.)

Cleanout

Door

Cleanout

Door

Cleanout

Door

This Distance Must Not Exceed 70% Of Total Rise

Baffle

30°

Max

Stagger

Entrances

A A

A-A

Tota

Rise

FIGURE 17  TYPICAL STACK AND FLUE INSTALLATION

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

2-33

Page 40

INSTALLATION FTA-IOM-2013-0227 SECTION 2

2'2'

Alternate Installation of Barometric Damper

Wrong Wrong Wrong

Poor

Wrong or Improper Installations of Barometric Damper

Wrong

Right

Right: Minimum 1 Pipe Diameter

Wrong: Less Than 1 Pipe Diameter

Proper and Improper Teeing of Damper

X = 3 TO 5 PIPE DIAMETERS ON EACH SIDE OF DAMPER

FIGURE 18  BAROMETRIC DAMPER INSTALLATION

2-34

Page 41

OPERATION

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE WARRANTY & PARTS

4 5

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-1

Page 42

OPERATION FTA-IOM-2013-0227 SECTION 3

! WARNING

Crystalline silica may be present in components of this equipment. Exposure

to crystalline silica may pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines o ered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

Start-Up Preparation & Installation Review

Review the installation section of this manual carefully. Con rm accordance with the Installation guidelines, including:

1. You have read and followed all safety information.

2. The equipment area is in conformance with established boiler room requirements. Review national and local codes.

3. There is total absence of water in pipework and  uid. To help the system, open all drains; blow dry air or nitrogen if available into a high point bleed through a pressure regulating valve.

4. There are no obstructions left in the  uid circuit from pressure leak testing such as blanking plates in  anged joints.

5. Pipework is free to expand naturally when hot. Open all valves to user circuits including air bleed valves at high points and drains at low points in the piping system, and the liquid level test connections in the expansion section of the combination tank.

6. Heater is located with the proper clearances as shown in Installation section of this manual.

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 quali ed to operate/maintain the equipment.

Defective or improperly installed equipment is hazardous. Do not operate equipment which is defective or improperly installed.

Never leave an opened manual air vent unattended. In the event an opened vent is left unattended, water or  uid damage could occur. The exception to this warning is a feed water deaerator manual vent cracked open may be left unattended.

Defective equipment can injure you or others. Do not operate equipment which is defective or has missing parts. Make sure all repairs or maintenance procedures are completed before using the equipment. Do not attempt repairs or any other maintenance work you do not understand.

7. Relief valves have been properly piped to a safe catchment.

8. Flue gas from the heater is properly vented.

9. Combustion air openings are not obstructed in any way and have adequate capacity.

10. There are no  ammable liquids, materials or hazardous fumes present in the environment.

11. Nothing was damaged or knocked loose during shipment and installation. Inspect the main gas train and trim assembly to be sure they were not damaged during shipment or installation.

12. Local authorities where approval for start-up is required have been noti ed. In some localities,  nal inspection of services may be required.

13. Installation checklist is complete.

Fill the System

The viscosity of thermal  uid is generally very high (500 cS) at ambient temperature. Below 50 F (10 C) some  uids become very thick. Fluid should be in a pumpable liquid form prior to  lling the system. Refer to the thermal  uid manufacturer’s recommendations.

Adhere to the following when  lling the system:

1. Refer to Figure 15 for the drain and  ll connection.

3-2

Page 43

SECTION 3 FTA-IOM-2013-0227 OPERATION

1. Filling must be carried out from the lowest point in the system in order to prevent air pockets from forming.

2. A drain and  ll point (generally a 3/4” threaded coupling) is provided on the inlet to the pump suction on skid-mounted units.

3. Typically a portable, high velocity pump, such as the type used for chemical transfer, is appropriate for  lling the system. Where only one or

two drums of  uid are required, a handheld pump may be practical.

¡ Filling Procedure for Systems Open to Atmosphere

Adhere to the following:

1. Follow the instructions in Fill The System section of this manual.

2. Check to see that the liquid level switch operates freely. To con rm

operation of the liquid level switch, manually trip the liquid level switch. Unit should shut down; pump will stop.

3. Fill the system slowly, closing all opened bleed and drain valves as  uid

reaches them.

4. When the  uid reaches and  ows from the expansion tank low level

manual test connection, begin slowing down the  lling process.

5. Close the low level connection and continue to  ll until the liquid level switch closes. After  uid appears in the low level connection, only a small amount of additional  uid should be required.

6. If  uid is observed coming from the expansion section high level manual test connection, drain  uid from the tank until the level is between the liquid level switch and the high level connection.

7. Filling is complete when the  uid has reached the lowest level in the expansion tank required to actuate the liquid level switch.

8. As oil reaches a vent, close it. After all vents have been closed, and you believe the system to be full, stop  lling. Start the circulating pump as described in Initial Start-Up: Cold Circulation section of this manual. Leave the  ll equipment connected as cleaning the strainer may create the need for more oil in the system.

9. Verify to see that the liquid level switch operates freely. To con rm operation of the liquid level switch, manually trip the liquid level switch. Unit should shut down; pump will stop.

¡ Filling Procedure for Systems Equipped with Inert Blankets

Adhere to the following:

! WARNING

Pressurizing a drum to force  uid into the system is not recommended. The drum may explode, creating a hazard to personnel and equipment.

During operation, any leaks are usually detected by a small amount of vapor. Leaks should be attended to as soon as possible because under certain circumstances, such as saturated insulation, thermal  uid can ignite when exposed to air and heat.

4 CAUTION

Do not use this equipment if any part has been under water (or subjected to heavy rains/water if the equipment does not have NEMA 4 wiring, controls and instrumentation). Immediately

call a quali ed service technician to inspect the equipment and to replace any part of the control system and/or gas control(s) which have been under water.

Commissioning/Start up by a nonFulton authorized person will void the product warranty.

Please read these instructions and post in an appropriate place near the equipment. Maintain in good legible condition.

The system pump is not to be used to  ll the system.

A pump that has been used for water

or a di erent thermal system should not be used prior to extensive cleaning. Thermal  uid may be damaged by contact with moisutre of other  uids.

1. Follow the instructions in Fill The System section of this manual.

2. Inspect the system to be sure all valves are open and all drains are closed.

3. Open all high point air vents.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

“Factory Trained Personnel” refers to someone who has attended a Fulton Service School speci cally for the equipment covered in this manual.

3-3

Page 44

OPERATION FTA-IOM-2013-0227 SECTION 3

! WARNING

Wear eye and hand protection for your safety.

Use extreme caution when opening circulating pump plug if system temperature is elevated.

Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full review of documentation available from the component manufacturer.

If a  re does occur, extinguish using CO2 foam or dry chemical. DO NOT USE WATER.

4. Do not pressurize the system with nitrogen at this point.

5. Inspect the liquid level switch (Figure 14) and be sure the switch is functioning properly.

6. Begin  lling the system.

7. Fill the system until the liquid level switch indicates there is oil in the expansion tank.

8. Pressurize the system slightly with nitrogen. Leave the high point vent connections open, as the nitrogen should be isolated from the vents by the oil in the system. The pressure required in the system at this point is only 2-3 psi. If too much pressure is applied, the nitrogen will bubble through the oil and vent to atmosphere. If this happens, reduce the pressure.

9. Continue  lling the system. If liquid level switch is made, be sure to observe the high point vents as oil is now entering the elevated portion of the pipe work. As oil reaches the vent, close it. After all vents have been closed, and you believe the system to be full, stop  lling. Start the circulating pump as described in Initial Start-Up: Cold Circulation section of this manual. Leave the  ll equipment connected as cleaning the strainer may create the need for more oil in the system.

10. Determine the  nal nitrogen pressure by measuring the di erence

between the D.A. Tank inlet and the highest point in the system. Divide that number by 2.31 (this will indicate the nitrogen pressure the system should be set for).

Installation in accordance with the guidelines within the manual should be fully completed before performing the initial start-up; and start-up must be complete prior to putting the unit into service. Starting a unit without the proper piping, venting or electrical systems can be dangerous and may void the product warranty.

11. If the tank is located outdoors and the inlet to the tank is the highest point

in the system, then 1-2 psig of nitrogen is su cient.

12. Adjustment can be made via the regulator mounted on top of the D.A. tank.

NOTE: ´ If you are using a  uid above its boiling point, the system must be

pressurized to overcome the vapor pressure of the  uid. Consult the factory for assistance.

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  uid in the casing. For pumps equipped

with mechanical or air-cooled seals, air must be bled out of the stu ng box area to ensure that thermal  uid has lubricated all seal and bearing

areas. Operation of the pump even a short time without bleeding  rst will damage the pump.

3-4

3. Use the thermal  uid as a barrier  uid. Remove the 3/8” plug at the barrier

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SECTION 3 FTA-IOM-2013-0227 OPERATION

 uid  ll port. Fill the cavity with thermal  uid until it comes out of the over ow tube. Replace the 3/8” plug.

¡ Pump With Mechanical/Air Cooled Seal

Adhere to the following:

1. Open the air bleed connection located directly over the pump shaft. Replace plug when a steady stream of thermal  uid, free of entrained air,  ows from the port.

2. If  ow has not started after two to  ve minutes, remove the coupling guard and rotate the pump shaft by hand in the proper direction. This should help move the cold viscous  uid through close tolerance seal areas. Replace plug when  ow is steady.

3. If this fails to induce  ow, introduce  uid through the bleed port and rotate the shaft by hand to work the  uid around the seal area. Continue to add  uid and rotate the shaft until no more  uid can be added.

4. Replace the plug and run pump for  ve to ten seconds. Stop the pump, remove the plug and wait for  ow to start. If after two minutes  ow has not started, add more  uid as described above and run the pump for  ve minutes.

! WARNING

4 CAUTION

Operation of the circulating pump for any amount of time without  rst bleeding will result in equipment damage.

If  uid temperature exceeds 150 F during start-up and no  ow has been induced, discontinue start-up and contact Fulton Service Department. Failure to do so may cause equipment damage.

5. Constantly check the bearing area (located immediately behind the casing) for overheating. Remove the plug and check for  ow.

6. If  ow has not started at this point, the  uid may be too viscous to move through the seal area. Start the system normally by selecting heat on the control panel, and raise the temperature 50 F. Continue to raise the system temperature by 50 F increments. Keep checking the pump until  ow starts.

NOTE: ´ If at 150 F (65.5 C) there is still no  uid  ow, discontinue start-up and

contact Fulton Service Department immediately.

7. The pump should not be subjected to thermal or pressure shock. The thermal  uid should, therefore, be allowed to  ow into the casing slowly.

8. Check  eld 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. The pump is properly aligned before it leaves the factory. Because the system expands in operation, the pump must be realigned when the system is at operating temperature.

11. Carefully check the coupling alignment of the pump and driver for angular and axial alignment. Check pump manufacturers instructions for these speci cations. The use of a dial indicator to check the axial and angular alignment is recommended.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-5

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OPERATION FTA-IOM-2013-0227 SECTION 3

! WARNING

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.

Operating this equipment beyond its design limits can damage the equipment and can be dangerous. Do not operate the equipment outside of its limits. Do not try to upgrade the equipment performance

through unapproved modi cations. Unapproved modi cations may cause injury, equipment damage, and will void the warranty.

Before commissioning the unit, verify with proper authorities that gas lines have been purged.

Check daily that the equipment area is free and clear of any combustible

materials, including  ammable vapors and liquids.

12. Realign at operating temperature, if necessary.

13. Make sure that the pump is properly greased or oiled.

¡ Pump with Packed Seal

Adhere to the following:

1. Make sure that the gland is  nger tight before  lling the system.

Start-Up Service

If start-up service has been included in the order, the factory should be contacted after the installation has been successfully completed and approved by the client’s representative or engineers. Where possible, contact the factory at least three weeks before a Fulton service engineer is required on site.

Consider the following in preparation for your on-site visit:

1. All procedures covered in manual sections Start-Up Preparation and Fill the System, including installation review, air testing of piping, pump alignment (where applicable), and  lling the system must be completed before the service person’s arrival.

2. Depending on the size of the system and the amount of service time contracted, start-up service includes  ring the heater, checking, verifying and adjusting all safety settings.

3. 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.

4. Service people will not commence start-up if there are obvious system de ciencies. However, start-up service in no way constitutes a system design check or approval of the installation.

3-6

5. In addition to commissioning the heater, the service person will also familiarize heater room personnel with the operation of all Fulton equipment. Personnel must be quali ed to understand the basic operation and function of controls.

Initial Start-Up

These instructions are for use when the unit is being started up for the  rst time, or after prolonged shutdown. They are to be used in conjunction with the speci c procedure information in manual section Routine Operation.

¡ Cold Circulation

1. Turn on the main power switches.

2. Check for proper  uid level in the expansion section of tank. See Figures 12

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SECTION 3 FTA-IOM-2013-0227 OPERATION

and 13.

3. A centrifugal pump cannot be operated with the discharge valve closed

without heating up dangerously.

4. The pump should be started with the suction valve full open and the discharge valve open a slight amount.

5. Check pump rotation. Operating the pump in reverse rotation may cause extensive damage.

6. Turn the three position switch located on the front of the panel box door to “Pump”.

7. Jog the green pump motor starting button and observe the direction of rotation. Rotation should be in the direction of the arrow shown on pump casing. If the rotation direction is incorrect, turn the three position switch

back to “O ” immediately. Change the wiring connections and recheck.

8. Check for proper alignment. Realign, at temperature.

9. With the control switch set to “Pump” push and hold the pump start button, check all manual resets on pressuretrols. The circulating pump will

run, but the burner will not  re.

10. If the pump stops when the button is released, check for proper  ow in the system, and review settings of high and low  uid pressure switches and

di erential pressure switch. Check liquid level switch.

11. Check that all pressure gauge readings remain stable. Refer to Figure

16. Pressure exceeding 100 PSIG or identical readings at inlet and outlet gauges indicate a closed valve.

12. If an extremely high vacuum (i.e. 15” Hg or more) is indicated on the compound gauge, the valve between the circulating pump and the combination tank may have been left closed. In this case, little or no pressure will be indicated by other gauges.

! WARNING

4 CAUTION

Do not use this equipment if any part has been under water (or subjected to heavy rains/water if the equipment does not have NEMA 4 wiring, controls and instrumentation). Immediately call a quali ed service technician to inspect the equipment and to replace any part of the control system and/or gas control(s) which have been under water.

A temperature exceeding 120 F** in the boiler room may cause premature failure of electrical components. Provisions should be made to maintain an ambient temperature of 120 F** or less (the panel box interior should not exceed 125 F**).

**Pumps, PLC or ModSync panels may require lower ambient temperatures or additional cooling.

13. Check all piping, connections and users for leaks. Repair any leaks immediately.

¡ Filtering the System

1. Initially, readings on the gauge will indicate zero or slightly positive

pressure. During the  rst few moments of  ow, this reading will go towards vacuum, indicating that the strainer is becoming plugged.

2. 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  ushed or pulled, cleaned and replaced.

3. In some cases, a positive pressure can be measured at the pump suction gauge (due to the use of a nitrogen blanket or large positive head). This should be noted and if the reading decreases by several inches or pressure, check the strainer to ensure it clean.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-7

Page 48

OPERATION FTA-IOM-2013-0227 SECTION 3

! WARNING

Before commissioning the equipment, verify with authorized personnel that the gas lines have been purged.

Never attempt to operate a heater that has failed to pass all the safety checks.

After checking controls by manual adjustment, make sure they are always reset to their proper settings. Contact your Fulton dealer before modifying the equipment.

If any “Manual Reset” limit device trips DO NOT reset without determining and correcting the cause. (Manual Reset Limits may include:  ame safeguard, high or low gas pressure, high temperature limit, high pressure limit)

WHAT TO DO IF YOU SMELL GAS : Do not use matches, candles,  ame or other sources of ignition to check for gas leaks. Do not try to light the 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. Follow the gas supplier’s instructions. If you cannot reach your gas supplier, call the  re department.

If excessive amounts of thermal  uid are to be vented from the system, additional thermal  uid may be required in the system. Contact Fulton for further information.

Flash steam may be generated at any point up to the operating temperature. Watch for gauge  uctuations.

If  uid or piping is added to the system, the boil out procedure is required, as water may have been introduced to the system.

4. Strainers should be cleaned by means of compressed air. A rag will merely force the smaller particles into the mesh of the strainer. It is recommended to place a lint free rag in the center of the strainer and blow air from the outside, trapping the debris in the rag.

5. Allow the pump to run again for several minutes and repeat the  ltering process until pump suction pressure remains steady after cleaning. The amount of time which must be allotted for  ltering varies with the system.

6. When the system is initially brought up to temperature, additional pipe scale and welding slag will loosen and enter the  uid stream. This will be trapped in the strainer causing vacuum at the pump suction.

¡ Boilout

1. Ensure adequate ventilation.

2. Check for correct fuel feed. All air must be eliminated from fuel lines, gas piping, preheaters, etc. by approved methods.

NOTE: ´ As the system is being boiled out, the piping must be checked

for leaks as the temperature of the thermal  uid is increased. If a leak is detected, refer to Thermal Fluids at Elevated Temperatures section in Installation section of this manual.

3. Open all manual valves in the fuel oil supply line. Do not run the fuel pump dry or without fuel lines connected to fuel source. Do not allow the fuel oil pump to pull a vacuum.

4. Check safeties.

5. Disable N2 blanket if equipped and open vent line on DA tank.

6. Set control switch to “Heat”. The burner will begin the call for heat if oil temperature is below setpoint.

7. With burner  ring and pump running, keep checking the gauges indicating pump and circuit pressures. Make sure they remain stable.

8. In case of pressure  uctuations, stop the burner, but allow the pump to continue to circulate  uid.

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 over ow 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  uid out of the expansion tank vent, turn

the heater o , but leave the pump on. This is to circulate the hot  uid through the piping without  ushing the steam too quickly. Once steam

and thermal  uid stop leaving the expansion tank unit, the heater can be turned on. Increase the temperature very slowly to prevent  uid from being forced out of the tank.

3-8

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SECTION 3 FTA-IOM-2013-0227 OPERATION

12. Continue bringing unit up to temperature slowly, with a temperature rise not exceeding 100 F (38 C) per hour. Do not exceed speci ed maximum outlet temperature. In the absence of speci c information, consult the factory before proceeding.

13. Once up to temperature, check the  uid level in the expansion section by opening the high level manual test connection. If a permanent  ow of  uid results when this valve is opened, and if all previous precautions have been followed, the expansion tank is too small for the capacity of the  uid in the installation. A larger tank must be installed.

14. After  fty hours of operation at operating temperature, check all  anges and connections for tightness.

¡ Combustion

Before  ring the heater familiarize yourself on the use of the controls, lighting, and shutdown procedures.

} SEQUENCE OF OPERATION FOR GAS FIRED BURNERS

The burner is of forced design. The sequence of operation is as follows:

1. The  ame programmer opens the main gas valve once stable pilot  ame is established.

2. Pressure regulators on both the pilot and main gas supply, supply pressure to the proper level.

NOTE: ´ Note the maximum inlet pressure rating of each regulator and

supply a step-down regulator if required.

! WARNING

A quali ed installer, service agency or the gas supplier must perform installation and service on the fuel delivery system.

During system boilout, it is imperative that all system legs or paths are open to ensure

 ow throughout the system. Never open a cool or unheated user leg of a system when the rest of the system is above 210 F ( 99 C).

Do not attempt to start the equipment for any testing prior to  lling and purging the vessel. A dry  re will seriously damage the equipment and may result in property damage or personnel injury and is not covered by warranty. In case of a dry

 ring event, shut o the fuel supply and allow the vessel to cool to room temperature before  uid is reintroduced to the pressure vessel.

3. Combustion air is delivered by a centrifugal blower fan. An air switch monitors the pressure and is part of the  ame programmer safety interlock circuit.

4. The  ame programmer monitors the safe operation of the burner. Functions include pre-purge of the combustion chamber, provision of ignition via the ignition transformer and electrode, opening the pilot gas valve, monitoring the pilot  ame signal via the  ame sensor, opening main gas valves and providing post-purge of the combustion chamber.

5. The  ame is monitored by a  ame sensor. In the event of insu cient,

unstable, or non existent pilot or main  ame, the  ame sensor will cause a safety lockout of the  ame programmer. Safety lockout can also be caused if the  ame sensor is improperly positioned or grounded. After fault has been corrected, reset by pressing the reset button on the casing of the burner control box.

} SEQUENCE OF OPERATION FOR ON/OFF BURNER

The sequence of operation for the on/o burner is as follows:

1. Beginning with power on, limit switch closed, fuel valves closed, and

When opening any drains on the equipment or piping system, steps should be taken to avoid scalding/burning of personnel due to hot  uids. Whenever possible, the system should be cooled prior to opening any drains.

Use only your hand to turn valve handles. Never use tools. If the handle will not turn by hand, don’t try to repair. Forced or attempted repair may result in  re or explosion.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-9

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OPERATION FTA-IOM-2013-0227 SECTION 3

! WARNING

Should overheating occur or the gas

supply fails to shut o , manually shut o the gas supply external to the equipment .

temperature controller calling for heat, the  ame programmer starts the cycle and the blower motor starts prepurge.

2. The air proving switch must be closed now. Air dampers remain in maximum position.

3. (Gas Pilot) Provided all safety interlocks are proven, ignition and pilot are energized and a timed trial for pilot ignition begins. After the pilot  ame is

proven, the main fuel valve is energized. Ignition is turned o when  ame is registered and the main gas valves open.

4. (Spark Ignition) At the end of purge time, provided all safety interlocks are proven, the spark is on and oil valves are opened. When the  ame is proven, the spark is shut o .

5. When the  uid temperature reaches the o setting (typically the setpoint plus 2 to 5 degrees) of the operating temperature controller, all fuel valves are closed.

The burner motor stops and the entire system is ready for restart on demand.

} MODULATING BURNER

The function of the  ame programmer must be greatly extended in a modulated system. Along with limit controls, operating controls and interlock devices, the programmer automatically controls the operation of the burner, blower motor, ignition, main fuel valves and modulating motor.

The sequence of operation is as follows:

1. Beginning with power on, limit switch closed, fuel valves closed, and modulating limit controller closed and calling for heat, the  ame programmer begins its cycle and the blower motor starts prepurge. The modulating circuit closes, driving the air dampers to maximum for prepurge.

2. The air  ow proving switch must be closed now. After timed prepurge, the modulating motor drives the air damper to its low  re position. All start interlocks must be proven or the  ame programmer will lockout.

3. Ignition and pilot are energized and a timed trial for pilot ignition begins. After the pilot  ame is proven, ignition turns o and the main fuel valve is energized. Pilot fuel is turned o and the modulating motor is released to automatic.

4. When the modulating motor is released to automatic, it receives its signal from the modulating temperature controller. The modulating motor then drives the modulating fuel valve and air damper in proportion to the heat demand.

5. During the initial call for heat, the modulating fuel valve and air damper will drive to their full- re position. As the temperature set point is approached, the modulating motor will continue to reduce the input until low- re position is reached. Input automatically increases and decreases according to load demand.

3-10

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SECTION 3 FTA-IOM-2013-0227 OPERATION

6. When the  uid temperature reaches the set point of the temperature controller or of the optional operating limit controller, all fuel valves will close and the  ame programmer will advance to the post purge cycle. When the postpurge cycle begins, the modulating motor will be in the low  re position. At the end of postpurge, the burner motor stops and the entire system is ready for restart on demand.

} OIL FIRED BURNER

The following refers to the design and operation of the on/o burner utilizing

fuel oil which requires no preheating. This burner is of high pressure, mechanical atomization design.

The sequence of operation is as follows:

1. An oil pump is used to obtain necessary atomizing pressure before the fuel

oil reaches the nozzle. The fuel oil is divided into  ne particles in the nozzle and imparted with a rotating motion before escaping from the nozzle as a cone of  nely atomized oil.

2. Combustion air is supplied by a centrifugal fan. A damper provides throttling of the inlet opening. The air from the fan reaches the burner head after going through a turbulator, accomplishing correct distribution and mixture of air and atomized fuel oil.

! 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.

4 CAUTION

Unburned oil, unlike gas, does not leave the combustion chamber during purge.

3. An electric spark between two electrodes provides ignition of the atomized mixture, except where code requires a gas pilot. This spark is produced by a high voltage transformer.

4. The  ame programmer circuit controls normal operation of the burner. The sequence includes purging of the combustion area for a set period, ignition and opening of magnetic valves on the oil circuit; post-purge of combustion area and return to re-start position.

5. A scanner mounted on the burner casing and facing the light of the  ame monitors the  ame.

6. Safety lock out occurs within a preset minimum time in the event of

insu cient, unstable or non-existent  ame. After fault has been corrected, reset programmer by depressing the reset button on the casing of the burner control box.

7. Proper fuel pressure at the burner nozzle is essential. The correct  ring rate

is obtained by setting the fuel oil pump to give the design pressure for each unit. This is done at the factory. Pressure is measured by connecting a 0-400 PSI (0-25 bar) test pressure gauge to the gauge connection on the fuel pump. The fuel pressure gauge indicates the pressure of the fuel at the burner nozzle.

8. Typical pressures range between 160-270 PSI (12-18.6 bar). Note the correct setting upon commissioning. Gauge readings should be recorded at start-up and checked periodically.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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OPERATION FTA-IOM-2013-0227 SECTION 3

4 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.

Flame Programmers

Refer to appropriate instructions for your unit’s  ame programmer, provided with the unit.

Operating Controls

The following speci cations, data, equipment and operating descriptions apply to typical heaters. These sections are provided for general information purposes only, and do not necessarily re ect the speci c details of individual systems.

At commissioning, the operation of all safeties and interlocks should be veri ed. Setpoints of all pressure and temperature switches as well as the programs for all programmable controls (temperature controls, temperature limits, operating controls, servo motors etc.) should be recorded for future reference. Contact the Fulton Service Department with any questions regarding the proper operation, set points and veri cation procedures for these controls.

The procedures below are used to verify functionality of the safeties and interlocks.

¡ Liquid Level Switch - When Combination Tank is Supplied

Adhere to the following:

1. Locate the liquid level switch (see Figure 14) and install prior to operation of the equipment. The liquid level switch is wired to the main heater panel. Failure to “make” this switch will result in lack of power at the panel.

2. In the event of system  uid loss, the level in the expansion section of the combination tank will drop, and the liquid level switch will shut the unit down. Control power will be lost to the panel.

3. To con rm operation, manually trip the liquid level switch. Unit should shut down; pump will stop.

¡ Air Safety Switch

1. The air safety switch is installed in the heater panel and is connected by tubing to the blower outlet. This switch requires that the blower fan deliver combustion air before energizing any fuel valves.

2. While  ring, disconnect the copper line from the  tting in the top cover of the air switch. The burner should shut down. Attempt to restart the unit by resetting the  ame programmer.

3. Blower motor will start, but  ring sequence should not begin.

3-12

4. Lockout of  ame programmer will occur.

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SECTION 3 FTA-IOM-2013-0227 OPERATION

¡ Blower Motor Starter

NOTE: ´ For units equipped with manual trip test button or motor starter.

1. While  ring, actuate the manual trip button on blower motor starter. Unit should lock out. Attempt re-start by resetting the  ame programmer. Purge cycle will not begin.

2. Reset motor starter; blower should start and purge cycle will begin.

3. Lockout of  ame programmer will occur.

¡ Pump Motor Starter

If a pump starter is supplied the pump motor starter will be located in the heater panel or pump skid. When the pump start button is pushed, the pump motor starter will engage the pump.

1. While  ring, actuate the manual trip button on the pump motor starter.

2. Pump and burner will shut down.

3. The blower should continue to run for approximately 30 seconds.

4 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.

4 CAUTION

Do NOT leave unit unattended in Manual Operation, in this mode the LMV51 will ignore its internal Set Point.

4. Attempt to restart pump by depressing the pump start push button.

5. The pump should not start. Reset starter and start pump.

¡ Diﬀ erential Pressure Switch

The di erential pressure switch (Figure 19) is mounted to the heater panel. Sensing lines connect this switch to both the inlet and outlet manifold of the

heater. This switch is critical and ensures proper  ow through the heater at all

times.

FIGURE 19  DIFFERENTIAL PRESSURE SWITCH

1. Proper setpoint is 2 psi below the published di erential pressure of the heater.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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OPERATION FTA-IOM-2013-0227 SECTION 3

4 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.

NOTE: ´ The di erential pressure will vary with heater model.

2. The heater is dependent on proper  ow for operation; therefore, a

di erential pressure switch is used to sense the pressure drop across the heater. The di erential pressure switch will shut the unit down in the event

of loss of  ow.

3. The di erential 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.

¡ High and Low Fluid Pressure Switches

The heater is equipped with a low inlet and high outlet pressure switch. See Figure 5. The switches are located on the side of heater panel with tubing connections to the respective heater inlet and outlet manifolds. The switches

are used to ensure proper  ow through the heater (no restrictions in the piping system). The switches must be set at startup and the setpoints are based on the system design/performance.

The only pressure required in the thermal  uid system is the pressure required to maintain the proper  ow. Pressure changes are monitored with these switches, which will shut the unit down in case of a change in the  uid  ow.

} TO TEST THE SWITCHES

1. With the three position switch set to “Pump”, remove the cover from the pressure switch and manually trip the switch. Pump should shut down.

2. Repeat for each switch; replace covers. Note, if the burner was on, it would also stop.

3. To set the inlet low  uid pressure cutout switch, raise the setpoint with the  uid at operating temperature and pump running, until the pump shuts down. Note the setpoint and lower by 10 PSI, then re-start pump. The setpoint at cutout should correspond to the reading on the inlet pressure gauge.

4. With the unit cold and pump running, lower the high  uid 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. With the unit running at operating temperature, lower the high outlet pressure switch until the pump shuts down. Note the setpoint and raise by 10 psi, then restart the pump. The setpoint of this switch should correspond to the outlet pressure gauge reading.

3-14

NOTE: ´ Switch settings shall never exceed the safety valve set pressure.

Page 55

SECTION 3 FTA-IOM-2013-0227 OPERATION

4 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.

FIGURE 20  HIGH/LOW GAS PRESSURE SWITCH

¡ Gas Pressure Switch

NOTE: ´ Gas Fired Units Only

The high and low gas pressure switches are located on the gas train See Figure

20. The switches are used to ensure that the incoming gas pressure and gas pressure to the burner are within the appropriate range.

1. While  ring, shut the main gas ball valve closest to the burner.

2. Unit will lock out on high gas pressure.

3. Attempt restart by resetting  ame programmer.

4. Unit will start purge and lock out.

5. Open the gas valve closest to the burner and reset  ame programmer.

6. Reset high side of switch, unit will start purge and  re.

7. To test the low gas pressure switch, close the incoming manual valve.

8. Allow the control to sequence.

9. When the gas valves energize, the heater should lock out.

10. Reset the low side of the switch/reset  ame programmer and open the

upstream manual valve.

11. The unit will start purge and  re.

¡ Operating Temperature Controls

The operating temperature control (Yokagawa, Honeywell) is located in the heater panel and regulate the cycling of the heater.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

3-15

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OPERATION FTA-IOM-2013-0227 SECTION 3

4 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.

1. The Fulton unit is a  red heat exchanger and the safe control and

monitoring of the thermal  uid temperature is of vital importance. The safe maximum temperature of the  uid must be strictly adhered to.

2. When consulting  uid manufacturer’s literature for the safe maximum  uid temperature, note that the temperatures quoted are the actual limit to which any of the  uids may be subjected. It is important to remember that in any  red heater there exists a “ lm” temperature which is higher than the temperature of the bulk of the  uid. Temperature controllers measure the bulk temperature and not the  lm temperature. This must be taken into consideration when setting the temperature controls.

3. Approximate guidelines for temperature settings are not to override the system design parameters.

4. These instructions should be used in conjunction with information from the system designer. Consult manufacturer’s literature.

5. Standard primary temperature control sensing point location for On/O

and Modulating heaters is on the heater outlet. For systems with multiple heaters manifolded together, the sensing point is on the heater inlet.

6. When optional inlet location of the primary controls is speci ed, the

following instructions may still be used with some modi cation. For instance when primary controls are located on the inlet, the dead band range will be much narrower than on heaters with outlet control. In addition, temperature changes will not be as immediately apparent.

7. An indicating temperature controller is used to regulate the thermal  uid

temperature. Typically the indicating control is a thermocouple.

8. The thermocouple is directly immersed in the thermal  uid in the heater manifold. The setpoint of the controller is regulated by the keypad.

¡ High Temperature Limit Switches Safety

All units are  tted with high temperature limit controllers which monitor the  uid temperature at the heater outlet. This limit controller provides over temperature protection. A high temperature limit switch acts as an over temperature safety device.

1. If the high temperature limit shuts down the unit, the manual reset button on the limit switch must be pressed after determining and resolving issue. The red button on the  ame programmer (or door reset) must also be pressed to reset the unit before it can be restarted.

2. The high temperature limit controller is factory set to 0 F. This must be set to the lowest of the following:

» Maximum operating temperature of the  uid.

» Maximum operating temperature of the equipment.

3-16

» 15 F (9 C) over maximum system operating temperature.

3. Do not set this controller too close to the normal outlet temperature in

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SECTION 3 FTA-IOM-2013-0227 OPERATION

order to avoid nuisance lockouts due to small transient over temperatures.

4. Several consecutive lockouts caused by the high temperature limit controller indicate the need for immediate installation review.

¡ Operating Limit Controller

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 may be adjusted per manufacturer’s instructions.

¡ On/Oﬀ Controls

Typically one controller is provided to sense the temperature on the heater

outlet. This controls the operation of the heater by switching it on and o .

1. An adjustable two point di erential between shut o and start up is built into the controller. This prevents frequent cycling of the burner. The

controller is set to provide the desired outlet  uid temperature. Due to the temperature rise through the unit, this may be considerably higher than the inlet temperature.

2. If the unit is equipped with an on/o controller, it will be located on the

face of the electrical cabinet. The temperature setpoint in the controller can be adjusted following the manufacturer’s instructions.

4 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.

¡ Modulating Controls

All gas- red models may be equipped with modulating controls.

1. The modulating temperature controller continuously regulates the outlet  uid temperature between the minimum  ring rate and high  re. When the unit is on low  re and the temperature continues to climb past the setpoint, the heater will shut down. It will typically re-start when the process temperature drops 7 F below setpoint.

2. Minimum load depends on the degree of modulation provided. Typically 2:1 modulation is provided, depending on the fuel selection and heater size. In this case minimum load is one half of full  ring rate.

3. The modulating temperature controller is set to maintain the desired  uid outlet temperature. Due to the temperature rise across the heater, this may be considerably higher than the inlet temperature.

4. If the unit is equipped with a modulating controller, it will be located on the face of the electrical cabinet. The temperature setpoint in the controller can be adjusted following the instructions in the component data sheet section of this manual.

¡ Pressure Gauges

All units have two pressure gauges measuring the thermal  uid pressure at the inlet of the heater and at the outlet of the heater. A third gauge measures the pump suction pressure.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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OPERATION FTA-IOM-2013-0227 SECTION 3

! 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 quali ed to operate/maintain the equipment.

1. The di erence between the readings of the two gauges indicates the

pressure loss across the heater. The di erence must not fall below the recommended value. Recommendations are based on heater size and are listed in this manual (see Table 9) and on the product data submittals on www.fulton.com.

2. The gauge indicating the pressure of the  uid at the inlet is labeled “Inlet“. The “Outlet” gauge indicates the pressure at the outlet, and in e ect indicates the resistance of the external pipework circuit. The pressure gauge indicating pressure at the inlet of the pump is labeled “Suction.”

¡ Test of Ignition Safety System Shutoﬀ

Test the ignition system safety shuto as follows:

1. Shut the pilot ball valve.

2. Close main gas ball between the inlet to the burner and the butter y valve.

3. With the main gas cock (inlet manual gas valve) open, the burner should be cycled on. After all the safety limits such as gas pressure and

temperature are satis ed, the blower will run and pre-purge the heater.

4. Once the purge is complete (30 seconds), the ignition transformer will be energized. There will be a 4 second trial for ignition period. During this period, indicator lights on the  ame safeguard (pilot).

5. With no  ame established, the  ame safeguard will not receive a  ame signal from the scanner.

6. After 4 seconds, the  ame safeguard programmer will assume a “Flame Failure” condition and go to a “lockout” mode. Lockout will require manual reset of the  ame safeguard.

7. After completing this test, open the gas valve.

¡ Cycle Testing

The heater should be cycled tested and automatically allowed to go through its normal starting sequence several times to verify that all components are functioning properly. This will also verify that combustion is set properly so that

heater light o has a smooth transition from ignition to main  ame.

A minimum of 10 cycles should be met without any  ame failures, with

combustion readings comparable to the factory test  re sheet and no interlocks causing the heater to shutdown.

Required Pressure Drop Across the Heater

The thermal  uid pressure drop across your heater is critical. This should be recorded at the completion of start-up, as follows:

3-18

1. The pressure drop value is obtained by subtracting the heater outlet pressure from the heater inlet pressure when the thermal  uid is at normal

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SECTION 3 FTA-IOM-2013-0227 OPERATION

operating temperature.

2. At the recommended standard  ow rates, and .7 sp gr, the pressure drop

cross the heater should be as shown in Table 9.

3. In the event of an abnormal reading, contact Fulton Service immediately. Failure to take immediate action in the event of reduced  uid  ow may result in rapid and serious degradation of the  uid, with possible damage to the heater.

TABLE 9  REQUIRED PRESSURE DROP ACROSS THE HEATER

Model Recommended

GPM (schedule 80)

FT-0200-A 90 21

FT-0380-A 90 21

FT-0520-A 125 24

FT-0690-A 125 24

FT-1050-A 150 20

FT-1740-A 200 26

Pressure Drop PSI

Procedure for First Shutdown

! 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 quali ed to operate/maintain the equipment.

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 speci cations. This should be done by means of a dial indicator.

2. Isolate Y-strainer(s) in system and clean regardless of pump suction pressure. Make sure that the temperature is low enough to handle safely or provision has been made to handle materials at high temperature. Generally, temperatures below 150 F (65.5 C) are acceptable to perform operation with regular work gloves.

3. With piping system cooled to ambient temperature, torque all bolts on skid and throughout system to gasket manufacturer’s speci cations using proper  ange torquing practices such as incremental torque increases, star pattern, etc. Refer to torque speci cations in Tables 5 - 8..

4. Visually inspect all thread  ttings and valve packings. Repair leaks and tighten valve packings to the point of stopping leak.

5. Upon putting unit back into operation, check all gauge readings. Note any discrepancies and contact Fulton.

Daily Start-Up

1. Check positioning of all system valves to ensure  ow is not dead-headed.

2. Visually check relative position of minimum level  oat switch in the

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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OPERATION FTA-IOM-2013-0227 SECTION 3

! 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 quali ed to operate/maintain the equipment.

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.

combination tank.

3. Turn on power supply switches.

4. Where applicable, open water cooling valve and check that water  ows

correctly. (For water cooled pumps only.)

5. Set three position switch to “Pump”. Push and hold manual pump start button, monitoring pressure gauges on heater.

6. When ready to begin heating, move three position switch from “Pump” to “Heat”. After a short delay resulting from the purge period, the burner will ignite. Make sure that the temperature setpoint is as desired.

7. On gas units, pilot valve activation will be indicated after pre-purge cycle has completed, followed by main  ame activation. Check the presence of the  ame by observing  ame signal strength from  ame programmer or testing device. Operator attendance during warm-up is a recommended precaution.

8. Start-up is considered complete when the unit begins to throttle back or shutdown on target temperature.

Daily Shutdown

1. Set control switch to “Pump” pump running, burner o .

2. Allow the  uid to circulate for approximately 20-30 minutes and then set the control switch to the “O ” position.

3. When using a water cooled pump, continue to circulate cooling water to

pumps for 30 minutes after stopping circulation.

4. Open power supply switches.

5. Units switched o by an automatic time switch should have an extra relay

 tted to allow 20-30 minutes of  uid circulation after stoppage in order to prevent localized over heating of  uid.

6. Close fuel valves if required. Closing of system valves is not generally necessary unless maintenance of components requires a partial draining of the system.

7. Because of the high temperatures usually applied, leaks are not expected to occur when cool down is achieved, provided pipework is free to contract naturally when cold.

3-20

Before Leaving the Installation

1. Check all controls to insure they are operating properly. Cycle the heater several times by raising and lowering operating temperature on the thermostat.

2. Make sure the installation complies with all applicable codes.

Page 61

MAINTENANCE

INTRODUCTION

INSTALLATION

1 2

OPERATION

MAINTENANCE

WARRANTY & PARTS

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

! WARNING

Crystalline silica may be present in components of this equipment. Exposure to crystalline silica may

pose signi cant health hazards, including but not limited to eye and respiratory system damage. Per the Centers for Disease Control and Prevention (CDC) and Occupational Safety and Health Administration (OSHA), appropriate Personal Protective Equipment must be worn to minimize exposure to hazardous substances. Refer to most current guidelines o ered by the CDC and OSHA for more information, including Personal Protective Equipment recommendations.

Required Equipment

The following minimum equipment is necessary to start and maintain fuel- red thermal  uid heaters:

§ Digital Multimeter

§ Combustion Analysis Equipment

§ Draft Gauge

Required Maintenance at First Shutdown

The thermal  uid 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.

1. While pump is still at operating temperature, align circulating pump(s) to pump manufacturer speci cations. This should be done by means of a dial indicator.

Prior to any maintenance concerning electrical components of this equipment, ensure electrical supply to the equipment is disconnected. Label all wires prior to disconnection; wiring errors may cause improper and hazardous operation.

Follow all proper lockout/tagout procedures for service.

Before beginning any maintenance, ensure area is free of any combustible materials and other dangers.

3. With piping system at ambient temperature, torque all bolts on skid and throughout system to gasket manufacturer speci cation using proper  ange torquing practices (incremental torque increases, star-pattern, etc). These values are available in the installation section of the manual..

4. Visually inspect all thread  ttings and valve packings. Repair leaks and tighten valve packings to the point of stopping leak.

5. Upon putting unit back in operation, check all gauge readings and compare to values given to you by the start up technician. Note any discrepancies and contact manufacturer.

Daily Maintenance Schedule

1. Complete the log sheet at least once per day as a minimum. It is recommended that the log sheet be  lled out twice per shift of operation. The log sheet is available from the Fulton Service Department, at the end of this section of this manual, and on www.fulton.com.

2. Make visual inspection of the entire system for leaks. Make repairs as soon as possible.

3. Note any failures on the  ame programmer noting fault number, fault code, fault annunciation, fault hour, fault cycle and fault time.

4-2

4. Check the exhaust for the presence of smoke. If smoke is present,

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

contact Fulton Companies at (315) 298-5121 or contact your local Fulton Representative.

5. In systems utilizing linkage, check all linkage components for tightness. See Figure 21.

FIGURE 21  LINKAGE COMPONENTS

6. In systems utilizing a water cooled thermal  uid circulating pump, check level of lubricating oil in self-leveling reservoir and check cooling water circulation loop for proper operation. See Figure 22.

! WARNING

Fluids under pressure are hazardous and may cause injury to personnel, or equipment damage, when released.

Shut o all incoming and outgoing

 uid shuto valves and carefully decrease all trapped pressures to zero before performing any maintenance.

Never use open  ame or other sources of ignition to check for gas leaks.

4 CAUTION

FIGURE 22  WATERCOOLED THERMAL FLUID CIRCULATING PUMP

Weekly Maintenance Schedule

1. Check inlet gas pressure at the beginning of the gas train. This should be accomplished by the installation of an appropriately scaled gauge.

2. Check manifold gas pressure at high and low  re and compare to Thermal Combustion Checklist  lled out by start up technician. This should be accomplished by the installation of an appropriately scaled gauge. Readings should be with .02” w.c. of Thermal Combustion Checklist.

Monthly Maintenance Schedule

1. Clean fuel  lters.

2. Check burner blower. Clean if necessary.

3. Clean or change air  lter if applicable.

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.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

Use caution when using any cleaning solutions. Refer to local regulations for proper cleaning solution disposal.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

4. Manually check  uid level in the expansion tank. Drain ½ gallon of thermal  uid from the expansion tank. If water is present, continue to drain ½

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-3

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

4 CAUTION

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

gallon until no water is present.

5. Check operation of all safeties. Refer to the instructions at the end of this section.

6. With the burner running, remove or disconnect the  ame detection device.

The  ame programmer should lockout within 3 seconds.

7. Review daily log sheets noting any deviations from the norm.

8. Check the tightness of all couplings, including the fuel oil pump drive (oil red units), fan impeller, circulating pump, etc. See Figure 23.

FIGURE 23  PUMP COUPLING

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 speci cations.

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 for sooting. If soot is present, it can be removed by utilizing a brush or compressed air for light sooting. See Soot Cleaning section of this manual.

4. Have combustion checked for e ciency.

5. Review daily log sheets noting any deviations from the norm.

Annual Maintenance Schedule

1. Replace the ignition electrode(s).

2. If the unit utilizes a  ame rod, replace.

4-4

3. Clean all strainers in the thermal  uid system.

4. Take a one quart sample of thermal  uid and return to the thermal  uid manufacturer for analysis.

5. Schedule local Fulton representative or factory service technician to

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

perform an annual preventative maintenance.

General Maintenance Procedures

¡ Lubrication

Di erent motor manufacturers recommend various intervals for lubrication schedules. Load variations will dictate the frequency and amount of lubrication required.

1. When developing your lubrication schedule, consider the thermal  uid pump and all system pumps.

2. If you have a thermal  uid circulating pump with a packed seal, the condition of the pump packing should be checed regularly. If  uid leakage

increases, tighten the packing ¼ turn daily.

¡ Soot Cleaning

If your vessel inspection indicates severe sooting, the following procedure should be followed:

1. Remove the burner and lower access doors.

2. Remove the top plate, then remove gasket.

3. Wire brush  ue passages and use compressed air where accessible.

! WARNING

4 CAUTION

Use extreme caution when using any cleaning solution. Refer to local regulations for disposal requirements.

In order to meet warranty conditions, ensure all appropriate maintenance activities are performed.

4. Vacuum loose soot where accessible.

5. Reinstall the burner and all access doors.

6. Fire the heater and set combustion.

Safety Check Procedures

Perform the following safety checks as needed:

¡ Liquid Level Switch

Manually turn liquid level switch cam counterclockwise. See Figure 14. Microswitch will open contacts and control voltage will be lost. Release cam and micro-switch will make and control voltage will be restored.

¡ Stack Limit

The limit manufacturer presets the stack limit. Testing can be performed by removing switch from stack and applying heat over that of the switch set point for several seconds. The switch can then be reset and re-installed. See Figure 24.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-5

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

! WARNING

Manual Reset

4 CAUTION

FIGURE 24  STACK LIMIT SWITCH

¡ Diﬀ erential Pressure Switch

With the circulating pump running, observe the di erence in pressure between the heater outlet gauge and the heater inlet gauge. Remove the top cover of the di erential pressure switch. Note the original setting of the switch and turn adjustment knob clockwise until switch trips. The pointer on the switch should be within 2 psi of the observed pressure di erence. Reset switch to the original set point. See Figure 25.

¡ Low Inlet Pressure Switch

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 di erential that is set.

¡ High Outlet Pressure Switch

Note the original setting of the switch and turn adjustment screw counterclockwise while observing heater outlet pressure gauge until switch trips. The pointer on the switch should be within 2 psi of the observed pressure. Reset switch to the original set point. See Figure 16.

4-6

FIGURE 25  DIFFERENTIAL PRESSURE SWITCH

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

¡ Air Switch

Remove the ¼” copper tubing from the bottom of the air switch with the fan running. Air switch should trip the interlock circuit. Re-attach copper tubing and reset  ame programmer.

¡ Air Filter Box Switch (if equipped)

With heater running at high  re, block opening to air  lter box by 50%. Slowly close o further until switch trips. Air  lter switch should trip at just over 50% blockage. Monitor combustion valves during this procedure.

¡ Temperature Limit(s)

Adjust set point(s) of temperature limit(s) down to a point lower than the process variable (PV). PV is typically the current  uid temperature at the heater outlet. Solid-state controls will deactivate a control relay powering a set of n.o. 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. Reset temperature limit if reset exists and reset  ame programmer.

¡ High/Low Gas Pressure Switch

! WARNING

4 CAUTION

Shut o the main gas valve prior to the gas train and attempt to light the unit. After the gas valves open during the ignition trial, the low gas pressure switch will trip. Reset the low gas pressure switch and  ame programmer. Open main gas valve prior to gas train and close gas valve between last actuated gas valve and burner. Attempt to light the unit. After the gas valves open, the high gas pressure switch will trip. Reset the high gas pressure switch and the  ame programmer, then open downstream valve.

Troubleshooting

} FLOW CIRCUIT/ CIRCULATING PUMPS

The  ow circuit is the electrical circuit that enables the circulating pump(s). Your thermal  uid pump(s) will remain on until the  ow circuit opens to disable the pump starter or the O / Pump / Heat switch is turned to the “O ” position. Items in the  ow circuit may include paddle type  ow switches, a high inlet pressure switch, a low inlet pressure switch, a high outlet pressure switch and a di erential pressure switch.

} LOW INLET PRESSURE SWITCH

All A-model heaters have a Low Inlet Pressure Switch. This is a normally open switch that closes with proper heater inlet pressure. This switch is generally a mercury bulb type switch. Mercury will rest towards the green cap of the mercury bulb in a “made” condition. The purpose of the Low Inlet Pressure Switch is primarily to protect the heater from a low  ow condition. The Low Inlet Pressure Switch should be set at 5 psi below normal heater inlet pressure as read at operating temperature assuming that none of the conditions indicated in Table 10-A are true. Refer to Table 10-A

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-7

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

! WARNING

4 CAUTION

for a tripped Low Inlet Pressure Switch.

} HIGH OUTLET PRESSURE SWITCH

All A-Model heaters have a High Outlet Pressure Switch. This is a normally closed switch that opens with excessive heater outlet pressure. This switch is generally a mercury bulb type switch. Mercury will rest towards the green cap in a “made” condition. The purpose of the High Outlet Pressure Switch is primarily to protect the heater from building too much pressure. Typical heaters have a maximum working pressure of 150 psi with 100 psi safety valve(s) on the heater outlet manifold. The High Outlet Pressure Switch should be set at 5 psi over the heater outlet pressure as read at ambient temperature assuming that none of the conditions mentioned in Table 10-B are true. Refer to Table 10-B for a tripped High Outlet Pressure Switch, which will require the manual reset button on the switch to be pushed.

} FLOW SWITCHES

Units older than mid-1993 have Flow Switches on the inlet of each heater.

These are normally open switches that close, making a micro-switch, upon  ow establishment. The purpose of the Flow Switch(es) is to protect the heater from too high of a

temperature and to protect the thermal  uid from exceeding its maximum  lm temperature. Each  ow switch is wired in series requiring  ow through each pipe . Refer to Table 10-C for  ow switch troubleshooting.

} DIFFERENTIAL PRESSURE SWITCH

Units newer than mid-1993 have a Di erential Pressure Switch. This is a normally open diaphragm switch that closes with a proper heater di erential pressure between the heater inlet and outlet. The purpose of the Di erential Pressure Switch is to protect the heater from too high of a temperature and to protect the thermal  uid from exceeding its maximum  lm temperature. Each heater model number has a speci c minimum di erential pressure. This pressure is the di erence in pressure between the heater inlet pressure gauge and the heater outlet pressure gauge. See Table 10-D for troubleshooting.

} CALL FOR HEAT/BURNER INTERLOCK

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. Generally these controls work in combination with a control relay. When the Temperature Controller calls for heat, a signal is sent to that closes a normally open set of contacts in series with the burner circuit. When the call for heat is met, the signal is removed and the contacts return to their open state. Situations that may interfere with the Call for Heat circuit are in Table 10-E. The burner interlock is the electrical circuit that enables the  ame 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  lter switch, auxiliary blower motor starter contacts, high temperature limit(s), high gas pressure switch, low gas pressure switch, and / or low oil

4-8

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

pressure switch.

} AIR SWITCH

All A-model heaters have an Air Switch. This is a normally open switch that closes with proper burner fan outlet pressure. This switch is generally a diaphragm type switch. The Air Switch is a safety device that proves that there is an adequate pressure and volume of make up air for proper combustion and mixing. There is no manual reset on the air switch itself to indicate a trip. The most likely time of an air switch trip is at low  re purge or low  re. If this switch trips, it is generally one of the issues indicated in Table 10-F.

} AIR FILTER SWITCH

A-model heaters with an air  lter box or ducted supply air have an Air Filter Switch. This is a normally closed switch that opens on too high of a suction pressure at the burner fan inlet. This switch is generally a diaphragm type switch. The Air Filter Switch is a safety device that proves that there is not too negative of a pressure at the combustion blower inlet. This switch is only used on units that have a built in air box for use as a duct connection or air  ltering device. There is no manual reset on the air  lter switch itself to indicate a trip. The most likely time of an air  lter switch trip is at high  re purge or high  re. If this switch trips, it is generally one of the issues indicated in Table 10-G.

} AUX. BLOWER MOTOR STARTER

All A-model heaters use an auxiliary set of contacts on their blower motor starter to prove that the burner motor is latched on. This is a normally open set of contacts mounted on or built in to the blower motor starter. The Auxiliary Blower Motor Contacts are a safety device that proves that the blower motor starter is latched in. These contacts work in redundancy to the air switch to prove that there is proper makeup air. There is no manual reset on the auxiliary contacts themselves to indicate a trip. If the contacts do not make, it is generally one of the issues indicated in Table 10-H.

} HIGH TEMP. LIMIT

All thermal  uid heaters have at least one High Temperature Limit. The high temperature limit(s) is/are normally closed switch(es) that break on a temperature rise over set point. The switch may be either a solid state controller or a bulb and capillary type switch. The High Temperature Limit is a safety

device that protects from excessively high temperatures. Solid-state high temperature limits will have a manual reset. Bulb and capillary type limits will not have a manual reset. If this/these switch(es) trips, it is generally one of the issues

indicated in Table 10-I.

} HIGH GAS PRESSURE SWITCH

All gas- red modulating thermal  uid heaters may have a High Gas Pressure Switch. This is a normally closed diaphragm switch that opens on a pressure increase over set point. The High Gas Pressure Switch is a safety device that protects the burner from receiving too high of a gas pressure. The switch senses this pressure downstream of the last gas valve, upstream of the modulation valve on units that modulate. This switch is most likely to trip at low  re. If this switch trips, it is generally one of the issues indicated in Table 10-J.

} LOW GAS PRESSURE SWITCH

All gas- red modulating thermal  uid heaters may have a Low Gas Pressure Switch. This is a normally closed diaphragm switch that opens on a pressure decrease below set point. The Low Gas Pressure Switch is a safety device that protects the burner from receiving too low of a gas pressure. The switch senses this pressure just downstream of the gas regulator. This switch will most likely trip at high  re. If this switch trips, it is generally one of the issues indicated in Table 10-K.

} LOW OIL PRESSURE SWITCH

All oil  red on/o thermal  uid heaters may have a Low Oil Pressure Switch. This is a normally closed diaphragm switch that opens on a pressure decrease below set point. The Low Oil Pressure Switch is a safety device that protects the burner from receiving too low of an oil pressure. The switch senses this pressure just downstream of the oil pump. If this switch trips, it is generally one of the issues indicated in Table 10-L.

} PILOT FLAME FAILURE

A Pilot Flame Failure is a  ame failure that occurs when the unit is trying to establish an adequate  ame signal. Solid-state 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  ame was not generated or the means of sensing the pilot  ame strength has failed. All gas  red units have a gas pilot. Oil  red units may be 2-stage, in which the 1st stage to light would be considered the pilot, or may have a gas pilot. In either case, during the pilot proving period, the  ame programmer must sense a strong enough  ame to initiate the opening of the main valves. See Table 10-M.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

} MAIN FLAME FAILURE

Main Flame Failure is a  ame failure that occurs while the unit is trying to establish an adequate  ame signal during the Main Flame Trial for Ignition. Solid state controllers indicate a Main Flame Failure by showing as a fault code of either Fault 19 for Honeywell 7800 series controllers, Flame Failure MTFI on Fireye E110 series controllers, or a Fault 09 for Fireye Nexus controls. For electromechanical controls, you need to witness when the failure occurs. A Main Flame Failure indicates that either a strong enough main  ame was not generated or the means of sensing the main  ame strength has failed. During the main  ame proving period, the  ame programmer must sense a strong enough  ame to hold the main valves open. If you are experiencing Main Flame Failures, check the items indicated in Table 10-N.

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

TABLE 10A  LOW INLET PRESSURE SWITCH TROUBLESHOOTING

Problem Potential Remedy

Plugged circulation pump

strainer basket

Failed Circulation Pump

Coupling

Cavitation of the

circulating pump

System is open Lack of back-pressure. If control valving is improper or pressure drop across the system is too low, the resulting

Blocked Sensing Line on

Pressure Switch

Improper Switch Setting Low Inlet Pressure Switch should be set at 5 psi less than the pressure read on the heater inlet pressure gauge at full

Switch is faulty If pressure is veri ed and reads correctly above set point on switch and the sensing line to the pressure switch is

TABLE 10B  HIGH OUTLET PRESSURE SWITCH TROUBLESHOOTING

Problem Potential Remedy

An obstruction

downstream of the heater

Improper Switch Setting The High Outlet Pressure Switch should be set at 5 psi over than the maximum pressure read on the heater

Faulty Switch If pressure is veri ed and reads correctly below set point on switch and the sensing line to the pressure switch is

A plugged strainer will result in a decrease of  ow through the heater. High vacuums developed from plugged

strainers can also stress the seals of the pump causing the pump to fail.

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.

If the strainer is plugged, isolate the strainer and drain that section of piping being mindful of the temperature of

the thermal  uid.

Remove the strainer and clean with compressed air, high-pressure water or a cleaning solution. Replace and

observe new pump suction pressure.

A failed coupling will result in a decreased or no  ow 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. If the coupling needs to be replaced, it is recommended to re-align

the circulating pump  rst at ambient temperature and again when it’s at operating temperature. Alignment should

be within pump manufacturers’ speci cations.

Cavitation occurs when a pump experiences a loss of head or if any low boilable  ashes to gas at the impeller.

During this time, the pump impeller spins without actually circulating any thermal  uid.

If Fulton Thermal Corporation provided the heater skid, loss of head to the pump is extremely unlikely with proper

 uid level in the combination tank.

The most common low boilable in a thermal piping system is water, which needs to be boiled out at startup or

anytime new piping or  uid is added to the thermal oil system.

Once the system has been brought up to full operating temperature, assuming that the entire system has seen

 ow, there should be no further occurrence of low boilable contamination apart from possible heat exchanger

failure.

minimal back-pressure may not provide enough resistance for the  ow to make the pressure switch. Check the

thermal  uid system for proper operation of control valves.

A blocked sensing line will give an inaccurate pressure reading to the pressure switch. A blocked line will need to

be replaced or cleaned. Most installations have block valves at the heater to facilitate safe isolation and cleaning of

the sensing line. Do not attempt when system is hot and running.

operating temperature of the system.

open, the pressure switch is faulty. Replace switch, set for desired set point and test for proper operation.

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).

Observe heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100%

bypass). Bypass regulating valve(s) should be adjusted to equal  ow condition through users.

Call or e-mail Fulton for further details. It may be possible that an automatic control valve has failed. If this is the

case, the valve actuator should be inspected and possibly replaced.

outlet pressure gauge during proper operation at the coldest ambient temperature expected.

open, the pressure switch is faulty. Replace switch, set for desired set point and test for proper operation.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

TABLE 10C  FLOW SWITCHES TROUBLESHOOTING

Problem Potential Remedy

An obstruction

downstream of the

Flow Switch(es)

Plugged circulation

pump strainer basket

Failed circulation pump

coupling

Cavitation of the

circulating pump

Any obstruction downstream of the  ow switch(es) will increase the pressure that the heater outlet sees. Any

increase in outlet pressure will result in diminished  ow. 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). Observe

heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100% bypass). Bypass

regulating valve(s) should be adjusted to equal  ow condition through users. Call or e-mail Fulton for further details.

It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced.

A plugged strainer will result in a decrease in  ow through the heater. High vacuums developed from plugged

strainers can also stress the seals of the pump causing the pump to fail.

A “Pump Suction” gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning.

Generally this point is -2 psi (5 in. Hg).

If the strainer is plugged, isolate the strainer and drain being mindful of the temperature of the thermal  uid.

Remove the strainer and clean with compressed air, high-pressure water or a cleaning solution. Replace and observe

new heater inlet pressure.

A failed coupling will result in a decreased or no  ow 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. If the coupling needs to be replaced, it will be necessary to re-align the circulating pump  rst at ambient

temperature and again when it’s at operating temperature.

Cavitation occurs when a partial vacuum presents itself at the eye of the pump impeller due to loss of head or if any

low boiler  ashes to gas at the impeller.

During this time, the pump impeller spins without actually circulating any thermal  uid. If Fulton Thermal

Corporation provided the heater skid, loss of head to the pump is extremely unlikely with proper  uid level in the

tank.

The most common low boilable in a thermal piping system is water, which needs to be boiled out at startup.

Once the system has been brought up to full operating temperature, assuming that the entire system has seen  ow,

there should be no further occurrence of low boiler contamination apart from heat exchanger failure.

TABLE 10D  DIFFERENTIAL PRESSURE SWITCH BREAK TROUBLESHOOTING

Problem Potential Remedy

An obstruction

downstream of the

heater outlet

Any obstruction downstream of the  ow switch(es) will increase the pressure that the heater outlet sees. Any increase

in outlet pressure will result in diminished  ow. 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). Observe

heater outlet pressure at temperature with all users / heat exchangers not calling for heat (100% bypass).

Bypass regulating valve(s) should be adjusted to equal  ow condition through users. Call or e-mail Fulton for further

details.

It may be possible that an automatic control valve has failed. If this is the case, the valve should be replaced.

TABLE 10E  CALL FOR HEAT CIRCUIT TROUBLESHOOTING

Problem Potential Remedy

Programming Problem Fulton has a general program for each of the temperature controllers we have used over the years. Compare your

current temperature controller program to Fulton’s general program.

See the back of this section for general programming sheets for standard Fulton heaters.

Make changes as necessary. Contact Fulton service department with any questions.

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

TABLE 10E  CALL FOR HEAT CIRCUIT TROUBLESHOOTING

Problem Potential Remedy

Temperature Controller

Failure

Temperature Sensor

Failure

Control Relay May Have

Failed

If the temperature controller is calling for heat but is not putting power on the output to the control relay, the relay

will not close the normally open contacts and the heater will remain disabled. If this is the case, some controllers

have separate sets of contacts that may be utilized in replacement of the damaged contacts. Some rewiring and/or

reprogramming will be needed. Contact Fulton service department if necessary.

Di erent temperature controllers use di erent types of temperature sensors. These may be Type J thermocouples,

mercury bulbs, RTDs or another type of sensor. It is possible for these sensors to malfunction. To verify proper

sensor operation, use an alternate source of temperature detection such as an infrared temperature sensor to sense

temperature at the same point.

Many temperature controllers energize a relay with a call for heat that in turn closes a normally open set of contacts to

energize the burner circuit.

If your temperature controller is sending an output signal to the control relay but the burner is not initiated, check

resistance across the relay. An open reading indicates that the relay 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.

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.

TABLE 10F  AIR SWITCH TROUBLESHOOTING

Problem Potential Remedy

Combustion Blower Fan

is Dirty

The sensing line is

plugged, crimped or

pointing in the wrong

area

The Switch setting is

improper

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  ow for the air switch to prove. You should assure that the combustion blower fan is

clean, reset the  ame programmer and try to light unit again

If the sensing line to the air switch is crimped or blocked, the switch will not sense the proper pressure. Ensure that

the sensing line is clear and not crimped by removing both sides of the sensing line and using compressed air to

blow through the line. Also ensure that the elbow acting as an air scoop is pointing directly into the air stream. Reset

the  ame programmer and try to light the unit again.

The adjustment screw for the air switch is located opposite the electrical connections. A gray cap covers the screw.

Turn the screw clockwise to increase setting, counter-clockwise to decrease setting. To set switch, run unit at low  re.

Increase setting 1/2 turn every 5 seconds until unit trips on interlock. Decrease setting by 2 full turns. Reset unit.

TABLE 10G  AIR FILTER SWITCH TROUBLESHOOTING

Problem Potential Remedy

The air  lter is dirty If the air  lter becomes dirty, the fan will generate greater suction. Too much suction will result in not enough air ow

for proper combustion and mixing and will cause air switch to trip. You should regularly change  lters on a schedule

dependent on how dirty the makeup air is. After checking or changing air  lter, reset the  ame programmer and try to

light unit again.

There is an obstruction

in the make-up air

ducting

The sensing line is

pointing in the wrong

direction

Units that have make-up air ducting need to assure that blockage to the ducting does not occur. Check outside

termination and any bends in the ducting for blockage. Clear blockage, reset  ame programmer and try to light unit

again.

The sensing line for the air  lter switch is supposed to provide the static pressure of the air box. The termination of the

sensing line should be pointing in the direction that limits its contact with moving air. If the sensing line is pointed

perpendicularly to entering air stream, the switch will not sense the proper pressure and could give a false indication of

air box suction. Reset the  ame programmer and try to light the unit again.

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

Switch setting is im-

proper

TABLE 10H  AUXILIARY BLOWER MOTOR STARTER TROUBLESHOOTING

The adjustment screw for the air switch is located opposite the electrical connections. A gray cap covers the screw.

Turn the screw clockwise to increase setting, counter-clockwise to decrease setting. The switch setting should be set

in such a way that with 50 % of the air box opening blocked, the switch will trip. Reset switch setting, reset the  ame

programmer, and try to light the unit again.

Problem Potential Remedy

The blower motor

starter coil is bad

The auxiliary contacts

are burned or pitted

TABLE 10I  HIGH TEMPERATURE LIMIT TROUBLESHOOTING

If this is the case, the blower starter will not latch in. Check for voltage to the coil. If proper voltage is present and the

starter does not pull in, that proves the coil is bad. Replace the starter, reset the  ame programmer and try to light

unit again.

Visibly inspect contacts. With power o , attempt to clean or replace starter if damaged. Reset  ame programmer and

try to light unit again.

Problem Potential Remedy

Flow rate is too low Too low of a  ow rate will result in a higher rate of heat transfer to the thermal  uid. This will result in a higher tem-

perature di erence between inlet temperature and outlet temperature.

It is important to make sure that the minimum  ow rate as speci ed by Fulton for that speci c model is maintained

Check inlet and outlet pressures of the heater to determine di erential pressure and  ow rate. Ensure that this  ow

rate meets or exceeds minimums speci ed by Fulton (see chart). Also check di erential pressure switch for proper

operation and setting.

Heater is over- red If the heater has more fuel input than design, it is probable that the heat transfer rate will increase beyond design.

Check input to heater at high  re for modulated heaters or at the standard rate for on / o units. This can be done by

either using a corrected gas meter reading or measuring gas pressure supplied to the burner compared to factory

test- re settings.

If input is improper, inspect burner as described below. If burner is not damaged or have improper components,

adjust fuel input and combustion to speci cation.

Gas- red burner is

damaged

Pull and inspect the burner. Primary areas of concern for gas- red units are the ori ce plate, pilot assembly seating

and ori ce plate gap.

If the ori ce plate is warped or burned through, pilot assembly is not seated or gap between ori ce plate and gas

tube is improper, more fuel than designed for will enter the furnace.

This will cause the heater to have more fuel input than designed for. The design  ow rate will then be too low

causing the  uid to heat up higher than it should.

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

TABLE 10J  HIGH GAS PRESSURE SWITCH TROUBLESHOOTING

Problem Potential Remedy

Gas pressure setting

on the main regulator

is too high

Low  re gas valve

setting is too low

Gas pressure switch

setting is improper

Gas regulator has

failed open

With unit running at high  re, make sure that the modulated gas valve is at full open.

Since unit lights at low  re, 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.

Check net last elbow gas pressure and compare to factory test  re sheet. Net gas pressure is running gas pressure

minus p urge pressure. Make sure net pressure reading is within .2” w.c. of factory reading. If there is a di erence,

adjust main regulator. Adjust for proper combustion throughout range.

Because the sensing point of the High Gas Pressure Switch is upstream of the modulating gas valve, the highest

pressure read will occur during low  re.

Check net last elbow gas pressure and compare to factory test  re sheet. Net gas pressure is running gas pressure

minus purge pressure. Make sure net pressure reading is within .1” w.c. of factory reading. If there is a di erence,

adjust modulating gas valve linkage. Adjust for proper combustion throughout range.

If above two items are proper, check the pressure that the high gas pressure switch is sensing by way of a tee

installed in the line. Hold unit at low  re and check pressure. Setting on switch should be 10% over pressure read. Call

Fulton if you have any questions.

This is highly unlikely. Regulators will usually fail safe in the closed position. The gas regulator can be checked by

checking upstream pressure and comparing to downstream pressure. Make sure that the upstream pressure is not

above the rating of the regulator. Make sure that the downstream pressure does not exceed the range of the spring.

If regulator has failed, replace, reset input and adjust input throughout the range.

TABLE 10K  LOW GAS PRESSURE SWITCH TROUBLESHOOTING

Problem Potential Remedy

Gas pressure setting

on the main regulator

is too low

Gas ori ce plate is

damaged

Gas regulator has

failed closed

At high  re, the modulating gas valve is full open resulting in the least amount of back pressure in the gas train. With

unit running at high  re, check net last elbow gas pressure and compare to factory test  re sheet. Net gas pressure

is running gas pressure minus purge pressure. Make sure net pressure reading is within .2” w.c. of factory reading. If

there is a di erence, adjust main regulator. Adjust for proper combustion throughout range.

If the ori ce plate is damaged, it may be holding back less gas creating a lower pressure on the sensing switch. Pull

burner and inspect gas ori ce plate. Plate should in no way be warped or degraded. If it is, replace. After reinstallation,

recheck input and adjust combustion throughout range.

Regulators will usually fail safe in the closed position. The gas regulator can be checked by checking upstream

pressure and comparing to downstream pressure. Make sure that the upstream pressure is not above the rating of

the regulator. If regulator has failed, replace, reset input and adjust input throughout the range.

TABLE 10L  LOW OIL PRESSURE SWITCH TROUBLESHOOTING

Problem Potential Remedy

Fuel oil pump may

have lost its prime

Fuel oil pump motor

may have failed

Fuel oil pump coupling

may have failed

An air bubble in the pump will result in a momentary loss of prime that will be enough to cause the Low Oil Pressure

Switch to trip. Ensure that oil pump is primed properly and all connections are tight. Check the pump seal. A blown

seal will allow air in the pump housing.

Check the pump motor for proper voltage. If voltage is proper but motor does not turn, replace or rebuild motor. If

there is no voltage, check motor starter for input signal and incoming 3-phase power.

A failed coupling will result in the pump not turning. Check coupling. Replace if necessary..

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

TABLE 10M  PILOT FLAME FAILURE TROUBLESHOOTING

Problem Potential Remedy

Pilot  ame strength is

inadequate

Pilot sensing device

does not work

properly

Room air pressure is

di erent from outside

air pressure

Cycle the unit. During the pilot trial for ignition, carefully observe the pilot  ame strength.

On Honeywell controllers, the pilot  ame strength must be between 1.25 to 5.0 VDC. On Fireye controllers, the pilot

 ame strength must be greater than 10 VDC.

Current controls are supplied with a test switch that can hold the programmer in the pilot trial for ignition stage. If a

pilot signal greater that 0.0 but less than the minimum required is detected, look through the sight hole provided on

the burner plate of the heater to visibly detect  ame. If  ame is seen, make small adjustments to increase pilot gas and

air to provide larger  ame.

Cycle the unit. If a pilot signal of 0.0 is detected, look through the sight hole provided on the burner plate of the heater

to visibly detect  ame.

If  ame is seen, your  ame detection device or ampli er may be faulty. If the unit has a  ame rod, lockout and tag

heater’s electrical circuit and fuel supply. Pull pilot assembly out of unit. Inspect the  ame rod. If the  ame rod is

corroded, shows isgns of heat impingement, has been burdned o or has cracks in the porcelain, replace with a new

 ame rod.

Reinstall and cycle unit. If the unit has a U.V. scanner, lockout and tag heater’s fuel supply. Remove U.V. scanner from

U.V. sight tube. Make sure that the lens of the scanner is clean. Use a lighter or match and make a  ame in front of the

scanner eye. Lens should  icker. If unti does not  icker, change U.V. scanner. If this change does not work, change U.V.

ampli er. Reinstall and cycle unit.

Check room air pressure relative to outside air pressure. Heater room pressure should equal outside air pressure.

Signi cant di erences in pressure will result in an erratic  ame, which will not deliver a strong  ame signal.

TABLE 10N  MAIN FLAME FAILURE TROUBLESHOOTING

Problem Potential Remedy

Main  ame strength is

inadequate

Flame sensing device

does not work

properly

Room air pressure is

di erent from outside

air pressure

Unit is experiencing

too great of a

restriction

Cycle the unit. During the main  ame proving period , carefully observe the pilot  ame strength. Current controls are

supplied with a test switch that can hold the programmer in the main  ame proving period.

If a main signal is greater than 0.0 but less than the minimum required is detected, look through the observation port

to try to visibly see  ame. A combustion change may be necessary to establish main.

If observed  ame is blue, slightly decrease the air damper setting and recycle. If  ame is red or orange, slightly

increase air damper setting and recycle. Once adequate  ame signal is established, reset input and combustion

throughout range of modulation.

Cycle the unit. If a signal of 0.0 is detected, look through the sight hole provided on the burner plate of the heater to

visibly detect  ame. If  ame is seen, your  ame detection device or ampli er may be faulty.

If the unit has a  ame rod, lockout and tag heater’s electrical circuit and fuel supply. Pull pilot assembly out of unit.

Inspect the  ame rod. If the  ame rod is corroded, shows signs of heat impingement, has been burned o or has

cracks in the porcelain, replace with a new  ame rod. Reinstall and cycle unit.

If the unit has a U.V. scanner, lockout and tag heater’s fuel supply. Remove U.V. scanner from U.V. sight tube Make sure

that the lens of the scanner is clean. Use a lighter or match and make a  ame in front of the scanner eye. Lens should

 icker. If unit does not  icker, change U.V. scanner. If this change does not work, change U.V. ampli er. Reinstall and

cycle unit.

Check room air pressure relative to outside air pressure. Heater room pressure should equal outside air pressure.

Signi cant di erences in pressure will result in an erratic  ame, which will not deliver a strong  ame signal.

At the breaching of the heater, take a draft reading. Draft should read between -.02” w.c. and -.04” w.c. with the heater

o and between -.04” w.c. and -.08” w.c. with the unit on. A restrictive draft would be a draft that was positive. A

restrictive draft is usually the result a stack that is undersized, a stack with too many elbows or a stack whose cap or

piping is warped and damaged. Another source of restriction results from broken refractory. If the unit’s refractory

breaks, large enough pieces could block the  ue passes. The burner should be pulled for refractory inspection. A

broken refractory should be cleaned out and replaced.

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SECTION 4 FTA-IOM-2013-0227 MAINTENANCE

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

4-17

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MAINTENANCE FTA-IOM-2013-0227 SECTION 4

4-18

Page 79

WARRANTY & PARTS

INTRODUCTION

INSTALLATION

1 2

OPERATION MAINTENANCE

WARRANTY & PARTS

3 4

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

5-1

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WARRANTY & PARTS FTA-IOM-2013-0227 SECTION 5

5-2

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SECTION 5 FTA-IOM-2013-0227 WARRANTY & PARTS

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. factory any part of the equipment, as de ned above, provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton. The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department. This warranty covers any failure caused defective material or workmanship. Thermal  uid system piping and valves are painted at the factory to protect from corrosion prior to installation and operation. These painted surfaces are not covered under warranty.

PARTS WARRANTY

Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one (1) year of shipment from the factory provided this equipment has been installed, operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton’s Quality Assurance department.

GENERAL

Fulton shall be noti ed in writing as soon as any defect becomes apparent. This warranty does not include freight, handling or labor charges of any kind. These warranties are contingent upon the proper sizing, installation, operation and maintenance of the boiler and peripheral components and equipment. Warranties valid only if installed, operated, and maintained as outlined in the Fulton Installation and Operation Manual. No Sales Manager or other representative of Fulton other than the Quality

Manager or an o cer of the company has warranty authority. Fulton will not pay any charges unless they were pre-approved, in writing, by the Fulton Quality Manager. This warranty is exclusive and in lieu of all other warranties, expressed or implied,

including but not limited to the implied warranties of merchantability and  tness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of pro ts or business, even if the Fulton Companies has been advised of the possibility of such damages. Fulton’s liability shall never exceed the amount paid for the original equipment found to be defective. To activate the warranty for this product, the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval.

Effective: 08.04.2011

Questions? Call (315) 298-5121, or visit us online at www.fulton.com

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PARTS & WARRANTY FTA-IOM-2013-0227 SECTION 5

! 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.

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. Factory-direct replacement parts must be used to ensure proper equipment operation and adherance with warranty requirements. Contact Fulton Companies at (315) 2985121 for further information.

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Page 84

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  uid heat transfer systems.

The heat transfer innovators.

The Fulton Companies

972 Centerville Road, Pulaski, NY 13142 Call: (315) 298-5121 • Fax: (315) 298-6390

www.fulton.com

FTA-IOM-2013-0227