FULTON FB-A 10 Instruction, Operation And Maintenance Manual Download Page 1

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Instruction, Operation,

and Maintenance

Manual
Fulton Gas Fired Steam

Boilers

HP to 60 HP

Serial Number: _______________________________

Model Number: _______________________________

Fulton Order Number: _______________________________

Sold To: _______________________________

Job Name: _______________________________

Date: _______________________________

Summary of Contents for FB-A 10

Page 1: ...s HP to 60 HP Serial Number _______________________________ Model Number _______________________________ Fulton Order Number _______________________________ Sold To _______________________________ Job...

Page 2: ......

Page 3: ...sheen or foam should be visible Iron Take a water sample Hold the sample against a white background The water should have no visible yellow red or orange tinge ND None Detected Parameter Carbon Steel...

Page 4: ......

Page 5: ...s d ASME hydrostatic test inspection e Electrical components inspection f Operating test g Final Engineering Inspection h Crating inspection NOTE The installation of the Fulton Gas Fired Steam Boiler...

Page 6: ......

Page 7: ...r Intake UL and MEA Approved Corrosion of Flue Pipe Installation Checkpoints Cleaning the Pressure Vessel Operation Starting the Gas Fired Boiler Gas Burner Set Up Gas Burner Set Up For Boilers Equipp...

Page 8: ...2 G 1 01...

Page 9: ...Safety Warnings Precautions 1 3 G 1 01...

Page 10: ...4 G 1 01...

Page 11: ...d be cleaned CAUTION Do not store halogenated hydrocar bons near or in the boiler room NOTE a The fused disconnect switch that controls the feed water pump should be kept in the on position at all tim...

Page 12: ...6 G 1 01...

Page 13: ...7 G 1 01 Description Instructions LE...

Page 14: ...8 G 1 01...

Page 15: ...18 5 19 5 19 5 19 5 19 5 MM 470 470 495 495 495 495 J Blowdown Outlet IN 15 25 15 15 16 5 16 5 16 5 MM 387 381 381 420 420 420 K Water Column Extension IN 14 14 14 14 14 14 MM 355 355 355 355 355 355...

Page 16: ...3 HR 384 403 606 807 1009 1210 9 13 w c req d M3 HR 10 8 11 4 17 2 22 9 28 6 34 3 Natural Gas Boiler IN 1 1 1 1 25 1 25 1 5 Connection Size Std CSD 1 MM 25 25 25 32 32 38 Oil Inlet Size IN 1 4 1 4 1 4...

Page 17: ...11 G 1 01 Operation LE...

Page 18: ...12 G 1 01...

Page 19: ...ay not fire at the first attempt due to air which must be purged from the gas lines This will result in the burner flame program mer going to lockout Repeat the procedure for starting the burner f The...

Page 20: ...14 G 1 01...

Page 21: ...15 G 1 01 Maintenance LE...

Page 22: ...16 G 1 01...

Page 23: ...gas regulator until last elbow pressure matches the test fire sheet NOTE Adjust air accordingly to ensure stable combustion during gas adjustments c Adjust air setting until combus tion readings are w...

Page 24: ...lace 3 Transformer Check voltage between transformer leads at terminal block to be sure transformer is being powered 4 Flame Safeguard Check voltage between ignition terminal and neutral Control Check...

Page 25: ...odes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 4 Scanner Check for dirt on flame scann...

Page 26: ...nd clean Check for proper location of detector 4 Draft Check draft with a gauge Draft should be a 02 to 04 W C with burner off or 04 to 06 when operating May need to install a barometric damper 5 Nega...

Page 27: ...when operating May need to install a barometric damper Boiler pushing water 1 Steam Traps Chech traps Clean or replace as necessary with the steam 2 Too much boiler Dump return tank and flush system...

Page 28: ...present but motor does not run replace it Low Fuel pressure 1 Gas pressure regulator Check and replace Boiler Flooding 1 Pump does not shut off Dirty probes Clean or replace as necessary 2 Relay faile...

Page 29: ...23 G 1 01 Parts LE...

Page 30: ...24 G 1 01...

Page 31: ...5 HP 2 91 2 12 253 Furnace Burner Tile 10 HP 2 91 2 12 221 Furnace Burner Tile 15 HP 2 91 2 12 254 Furnace Burner Tile 20 30 HP 15 6 8 5 21 6009 Burner Scroll 9 5 HP 30 13 6 5 21 6010 Burner Scroll 1...

Page 32: ...26 G 1 01...

Page 33: ...Boiler Description Instructions Gas Fired Boiler 2 27 G 1 01...

Page 34: ...QQQQQQQQQQQQQQQQQ QQQQQQQQQQQQQQQQQQQQQ Transformer Scroll Gaskets Steam Gauge Assembly Gauge Glass Valve To O P C To H P C Burner Motor Gauge Glass Valve Gauge Glass And Protector Water Column Contro...

Page 35: ...9 85 MM 1070 1320 1575 1473 1600 1675 1728 1867 2007 2159 H Feedwater Inlet IN 27 33 33 5 33 33 5 34 34 34 35 35 MM 685 840 851 840 851 865 865 865 890 890 I Handholes IN 19 19 19 19 19 19 19 19 20 20...

Page 36: ...257 398 419 628 837 1047 1256 2093 2511 7 11 w c req d M3 HR 4 8 7 1 11 3 11 9 17 8 23 7 29 7 35 4 59 3 71 1 Natural Gas ICX FT3 HR 159 242 384 403 606 807 1009 1210 7 11 w c req d M3 HR 5 6 6 9 10 8...

Page 37: ...30 G 1 01 Description Instructions I E K K J K D C H B A G F...

Page 38: ...per size to ensure adequate gas supply to the gas head assembly Consult your gas company for specific recommen dations e For natural gas a pressure of 7 to 11 178mm to 279mm of water col umn pressure...

Page 39: ...NOTE Where a condensate return tank is to be fitted this should 1 Be vented to a safe location and 2 Have a capacity sufficient to satisfy boiler consumption as well as maintain proper return tank tem...

Page 40: ...alve is supplied with the unit b In a closed system an end of the line trap should be installed c There are three blow off valves on the boiler the main valve at the rear of the boiler the gauge glass...

Page 41: ...a pipe size equal to or greater than that of the valve outlet Use schedule 40 discharge pipe only Do not use schedule 80 extra strong or double extra strong dis charge pipe or connections It must be...

Page 42: ...25 60 1 25 2 When feeding the boiler using a return system the city water pressure should not exceed 40 PSI A pres sure reducing valve should be installed a head of the return tank when above this pr...

Page 43: ...g from the fittings and place them in the same order on to both ends of the gauge glass Push both packings about an inch up the gauge glass 7 Gently insert one end of the glass into the top gauge fitt...

Page 44: ...te the boiler metal and are usually covered with tuber cles of iron oxide Once pitting starts it may be extremely hard to arrest Pitting can proceed at a surprisingly rapid rate and can occur not only...

Page 45: ...king a bot tle containing boiler water If oil is present foam will result To ensure the foaming is being caused by oil add a small amount of powdered activated carbon to the bottle con taining the boi...

Page 46: ...one at a high er level in the boiler room wall This will provide a flow of air to exhaust the hot air from the boiler room Room temperature not to exceed 100 F c The following openings are recommended...

Page 47: ...ack to avoid hav ing too great a load imparted to the flue outlet connection of the boiler e The proper flue size and draft control is most important for proper burner operation The flue must be as la...

Page 48: ...equal to or greater than 50 square inches 3 A mesh screen shall be affixed to the air inlet with openings of approxi mately 1 2 x 3 4 4 The total length from outdoors to the boiler intake shall not e...

Page 49: ...m safety valve opening 4 The mixture of washing soda to water is as follows Boiler Size Soda 4 6 1 lb 454g 10 15 2 lb 908g 20 30 3 lb 1362g 40 50 3 1 2 lb 1589g 60 4 lb 1816g 5 Replace the steam safet...

Page 50: ...42b G 1 01...

Page 51: ...43D G 1 01 Operation 3...

Page 52: ...43b G 1 01...

Page 53: ...feed valve on the boiler 5 Open valves on makeup water line to return if return system is used 6 Place feedwater pump fused switch in the on position NOTE a The fused disconnect switch that controls t...

Page 54: ...ve giving a main flame e Fulton 4 30 h p natural gas fired boilers can be equipped with flame rods or UV scanners f All Fulton propane or butane boil ers and 50 and 60 HP Fulton natural gas boilers ar...

Page 55: ...per combustion characteristics f The modulating burner will have a modulation lock switch in the panel box to enable you to lock the firing sequence anywhere along the firing rate from low to high g D...

Page 56: ...high low gas valve e The end of the linkage arm that goes to the gas valve will have a notch on both sides of where the swivel collar should be centered This setting was based on factory test fire con...

Page 57: ...proportionately divide the air to the center or outer fire chamber By mov ing the damper closed the air is forced to the outside of the fire chamber with less air going down the blast tube area By pul...

Page 58: ...ssure falls below a predetermined level e Sight Glass Isolation Valves The brass sight glass isolation valves are equipped with an internal ball check In the event that a sight glass should break the...

Page 59: ...Maintenance 4 5 G 1 01...

Page 60: ...51 G 1 01...

Page 61: ...QQQQQQQQQQQQQQQQQQQQQ Transformer Scroll Gaskets Steam Gauge Assembly Gauge Glass Valve To O P C To H P C Burner Motor Gauge Glass Valve Gauge Glass And Protector Water Column Control Box High Density...

Page 62: ...s in water column Make sure there is no pressure on the boiler during the removal of the probes Remove one probe using a 7 8 socket clean with very fine emory cloth and replace it before removing anot...

Page 63: ...pplies may need adjusting If a flame rod is cracked or broken the porcelain will have to be replaced to get a proper signal Flame Scanner Adjustments for Fulton Gas Fired Steam Boilers a Flame scanner...

Page 64: ...tory is to be changed the bottom refractory need not be broken f Round and bevel the outer edges of the new refractories g The bottom refractory has the largest hole while the top refractory has the s...

Page 65: ...ay make sure ignition and burner are working properly f Check water level in sight glass g Check to be sure feed water pump is working h For float type water level control blow down float chamber Reco...

Page 66: ...pressure on the boiler dur ing the removal of the probes 6 Check refractories for soot or breakage and inspect the stainless steel ring 50 and 60 HP only 7 With the boiler under no more than 15 PSI pr...

Page 67: ...ter a new Fulton Boiler has been in operation for several months pieces of burned metal will be found in the space at the bottom of the boiler These pieces of metal are the remains of a light gauge me...

Page 68: ...oltage between ignition terminal and neutral Control Check must be made before control locks out on safety If no power replace control 5 Faulty Air Switch Check for bad air switch by jumpering the two...

Page 69: ...rodes Check electrodes for carbon buildup and clean if necessary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 4 Flame Rod Adjustment Check flame rod...

Page 70: ...essary Check for proper adjustment Readjust if necessary Check for cracks in porcelain if found replace 3 Flame rode adjustment Check flame rod for carbon buildup and clean if or UV Scanner necessary...

Page 71: ...water treatment company 5 Too much water Have water tested by water treatment company softener high PH 6 Too much of a load Check total equipment horsepower required against horsepower of boiler bein...

Page 72: ...Water pump will not 1 Scale on probes Check and clean or replace as necessary come on at times 2 Bad Pump Contactor Check to see if contactor is being powered Check to see if contactor coil is pulling...

Page 73: ...Parts 5 6 G 1 01...

Page 74: ...F Edge second flue gas pass rib heat transfer pattern and cannot be converted to fire 2 oil These boilers will also require use of the Edge cleanout brush in lieu of the standard The Edge cleanout bru...

Page 75: ...ure that the full information given in the Parts List is supplied together with the following details as shown on your boiler identification plate 1 Boiler Number 2 Boiler Type 3 Electrical Specificat...

Page 76: ...0 355 Flue Cover Ring 15 HP 20 5 9 32 5 10 357 Flue Cover Ring 20 HP 21 9 55 5 10 359 Flue Cover Ring 30 HP 25 11 36 5 10 360 Flue Cover Ring 40 60 HP 40 18 18 5 12 001 Bottom Cleanout Access Plate wi...

Page 77: ...air Kits 40 60 HP 9 5 4 32 2 21 053 6 Stack Connection 4 10 HP 6 5 2 95 2 21 054 8 Stack Connection 15 HP 7 3 18 2 21 055 10 Stack Connection 20 HP 7 5 3 41 2 21 056 12 Stack Connection 30 60 HP 8 3 6...

Page 78: ...ll Casting 9 5 HP 14 6 36 2 11 123 Burner Scroll Casting 4 15 HP 30 13 64 5 20 059 Burner Scroll Casting 20 HP 35 15 91 5 20 060 Burner Scroll Casting 30 HP 40 18 18 5 20 061 Burner Scroll Casting 40...

Page 79: ...55C 1 5 2 27 2 40 252 Gas Valve Body P O C V5055C 1 1 4 5 1 2 32 2 40 253 Gas Valve Body P O C V5055C 1 1 2 4 7 2 14 2 40 254 Gas Valve Body P O C V5055C 2 9 3 4 23 2 40 214 Actuator for 2 2 1 2 and 3...

Page 80: ...Orifice 10 HP 2 0 91 7 20 033 Propane Orifice 15 HP Post 2 89 1 2 0 91 7 20 063 Propane Orifice 15 HP Pre 2 89 1 1 4 2 5 1 14 7 20 064 Propane Orifice 20 HP 3 1 36 7 20 065 Propane Orifice 30 HP 3 1...

Page 81: ...2 27 7 54 1005 Gas Train Assembly 30 HP Natural Gas 27 12 27 7 54 1006 Gas Train Assembly 40 50 HP Natural Gas 70 31 82 7 54 1007 Gas Train Assembly 60 HP Natural Gas 70 31 82 7 54 1050 Gas Train Asse...

Page 82: ...mn 11 1 4 0 3 0 14 2 20 017 Low Water Probe in Boiler 17 1 8 0 5 0 23 2 21 012 Probe Cover 2 1 0 45 2 21 013 Probe Cover 4 1 0 45 2 30 398 1 4 Male Female Ball Valve for Water Column 0 6 0 27 2 40 021...

Page 83: ...BSC 24 0 45 0 2 2 40 572 Overload AB BSB 42 0 45 0 2 2 40 573 Overload AB BSB 60 0 45 0 2 2 40 574 Overload AB BSB 80 0 45 0 2 2 40 566 Overload AB BSB 90 0 45 0 2 2 40 200 Motor Starter Relay 120V 20...

Page 84: ...e Blowdown Valve 200 8 4 3 82 2 30 007 1 Quick Action Blowdown Valve 13 5 91 2 30 014 1 1 4 Quick Action Blowdown Valve 14 6 36 2 30 023 1 1 2 Quick Action Blowdown Valve 23 10 45 2 40 133 Timer for A...

Page 85: ...5 0 23 2 30 334 0 60 PSI Steam Pressure Gauge 0 5 0 23 2 30 333 0 200 PSI Steam Pressure Gauge 0 5 0 23 2 30 332 0 300 PSI Steam Pressure Gauge 0 5 0 23 2 30 327 0 600 PSl Steam Pressure Gauge 0 5 0...

Page 86: ...r Gauge Glass Rubber 2 2 12 000020 Water Gauge Glass Fiber 1 2 20 000019 Ignition Electrode 1 5 10 000397 Tee Handle Wrench 1 4 30 000052 Set of 4 Plugs and Probes 2 12 515 Burner Plate Gasket 4 HP Ga...

Page 87: ...0 60 HP 1 0 45 2 12 518 Top Plate Gasket 4 HP Old Style 1 0 45 2 12 519 Top Plate Gasket 4 15 HP 1 0 45 2 12 520 Top Plate Gasket 20 30 HP 1 0 45 2 12 521 Top Plate Gasket 40 60 HP 1 0 45 4 12 522 9 5...

Page 88: ...79 G 1 01 Parts...

Page 89: ...40 50 2 30 425 9 3 16 X 2 1 2 x 1 LP N Gas 50 60 60 The correct part number is located on the back of the fan plate Part No Ignition Transformer 4 2 40 082 120 60 1 2 40 083 240 60 1 2 40 084 120 50 1...

Page 90: ...81 G 1 01 Parts Gas Burner Ignition Assembly Gas Burner Components...

Page 91: ...0 116 Main Gas Manual Shut Off Valve 60 2 30 104 Main Gas Pressure Regulator 2 4 15 2 30 105 Main Gas Pressure Regulator 20 2 30 107 Main Gas Pressure Regulator 30 50 2 30 108 Main Gas Pressure Regula...

Page 92: ...83 G 1 01 Parts 1 2 9 10 11 6 8 3 2 5 4 7 6 8 9 10 11 1 Gas Head Assembly CSD 1 4 to 50 HP Gas Head Assembly CSD 1 60 HP...

Page 93: ...2 40 201 Motor Starter Relay 220V 20 AMP 4 50 2 40 203 Motor Starter Relay 220V 30 AMP 4 50 Part No Flame Safeguard Control HP 2 40 260 RM7895F Programmer 4 50 2 40 262 RM7800M Programmer 60 100 2 40...

Page 94: ...ss Water Gauge Glass Gasket 4 4 100 2 12 019 Rubber Water Gauge Glass Gasket 5 4 100 2 35 514 Brass Packing Nut for Gauge Glass Valve 6 4 100 2 30 330 Gauge Glass Protector Rods 7 4 100 2 12 022 Lucit...

Page 95: ...Warranty 6 8 G 1 01...

Page 96: ...87 G 1 01...

Page 97: ...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...

Page 98: ...89 G 1 01...

Page 99: ...nt 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 manu...

Page 100: ...91 G 1 01...

Page 101: ...Component Data Sheets 7 G 1 01...

Page 102: ......

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FULTON FB-A 10, Instruction, Operation And Maintenance Manual

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