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FULTON FT-0080C, Installation, Operation, Maintenance And Parts Manual

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FULTON FT-0080C Installation, Operation, Maintenance And Parts Manual Download Page 58

FT-C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1

Page 50

3

3.9 

OPERATING CONTROLS

The following specifications, data, equipment and operating descriptions apply to typical Fulton 

thermal units. These sections are provided for general information purposes only, and do not 

necessarily reflect the specific details of individual systems.

At commissioning, the operation of all safeties and interlocks should be verified.

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 verification procedures for 

these controls.

FIG. 21  CONTROL PANEL FASCIA

Alarm Buzzers

Power On Indicator

Flame Sensor Light and 

Reset Button

Oil Valve Open 

Indicator

Deaerator Low 

Level Indicator

Fan On Indicator

Thermal Fluid Pressure 

Alarm and Reset Button

High Limit Temperature

Fuel Pressure Alarm 

Indicator

Door Isolator

Heater On/

Off Switch

Ignition Indicator

Operating Temperature 

Controllers

Pump Run Indicator

Pump On/Off Switch

Summary of Contents for FT-0080C

Page 1: ...ectric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Fulton Ltd FT C Fuel Fired Thermal Fluid Heater This Manual must be available to the heater operator at all times INSTALLATION OPERATION MAINTENANCE...

Page 2: ...nd safe manner SAFETY The instructions provided for the operation and maintenance of the system MUST be observed Failure to do so could result in damage to the boiler and serious personal injury SAFET...

Page 3: ...is in good condition WARNING Operating the heater beyond its design limits can damage the heater it can also be dangerous Do not operate the heater outside its limits Do not try to upgrade the heater...

Page 4: ...em 2 9 4 Location 2 9 5 Pressurised Systems 2 9 6 Connections 2 9 7 Oil and Gas Circulating Pump 2 10 Location 2 10 1 Connections and Piping 2 10 2 Alignment 2 10 3 Lubrication 2 10 4 Seals 2 10 5 Air...

Page 5: ...Motor Starter 3 9 5 High and Low Fluid Pressure Switches 3 9 6 Gas Pressure Switch 3 9 7 Operating Temperature Control 3 9 8 High Limit Temperature Control 3 9 9 Pressure Gauges 3 9 10 Operating Limit...

Page 6: ...leshooting Tripped High Outlet Pressure Switch 4 5 2 Troubleshooting Differential Pressure Switch Break 4 5 3 Troubleshooting Call for Heat 4 5 4 Troubleshooting Safety Interlock 4 5 5 Maintenance Log...

Page 7: ...auges 13 Typical Thermal Piping Shematic 14 Bolting Seqeunce 4 and 8 Bolt Flanges 15 Drain and Fill Connections 16 Proper Fluid Level in Dearator Tank Expansion Section 17 Oil Nozzle Dual Fuel Burner...

Page 8: ...cal thermal fluid heater Electrical panel box contains all operating safety controls FT L combination expansion dearaetor thermal buffer tank Thermal fluid circulating pump Skid mounted FT C thermal f...

Page 9: ...inimal refractory lining shall be supplied in heater combustion chamber to avoid thermal inertia and overheating of the thermal fluid should a pump or power failure occur The shell coil and burner are...

Page 10: ...is of four pass combustion design 2 First pass radiant combustion air enters burner fan and travels upward between inner and outer jacket before it enters top mounted burner 3 Second pass convection...

Page 11: ...circulating pump should this occur In applications where it is desirable to design to pressures lower than 6 9 barg 100 psig an alternative safeguard is to install appropriately sized safety valves e...

Page 12: ...eights given in section 5 1 Check building specifications for permissible floor loading e The heater should be placed in a suitable heater house or well ventilated separate room through which personne...

Page 13: ...y a non stacking tight shutoff 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...

Page 14: ...nual Gas Valve Butterfly Valve HI LOW Gas Pressure Switch 2 N P T Gas Connection 2 N P T Gas Connection Manual Gas Regulator Manual Gas Valve Vent Valve Gas Safety Shutoff Valve Manual Gas Valve HI LO...

Page 15: ...sheet 2 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 fitted into the return pipe Fuel Oil Viscosity Spec...

Page 16: ...instructed not to commence commissioning if hazardous conditions exist 2 6 ACCESS a Access around the heater should be provided to facilitate maintenance Appropriate clearances for all sides follow b...

Page 17: ...ble connector b The heater outlet should be piped directly to the system via an isolating valve c A safety relief valve may be shipped in the parts box accompanying the electric heater and must be ins...

Page 18: ...ill be shipped in the parts box and must be installed in the field Multiple skid systems may require wiring between the skids d If the unit is not skid mounted at the factory the client contractor is...

Page 19: ...ory The customer should confirm the expansion rate of the chosen fluid and system volume 2 9 2 deaErator section At start up the primary purpose of the deaerator section is to remove all volatiles fro...

Page 20: ...5 litres x 1 25 945 litres 945 755 190 litres expansion The FT 200 L has only 75 litres available for expansion so the correct selection is the FT 500 L 2 9 5 location a The combination tank must be i...

Page 21: ...13 2 Expansion Volume Vent for piping to Safe Catchment Expansion Tank Hot Fluid Medium Fluid Cool Fluid Gases Steam Thermal Buffer Section Drain Fluid Out Liquid Level Switch Fluid In Dearator Sectio...

Page 22: ...point in the piping system In conjunction with this system an automatic venting device must be fitted to the system expansion tank Consult Fulton Ltd for further details The location for the liquid l...

Page 23: ...te the inlet The low level is on the centre line of the tank the high level is next to it slightly off centre The high level rises up from the bottom of the tank and ends 100 mm below the top the low...

Page 24: ...PUMP Installing the pump in accordance with the manufacturer s specifications and these instructions will prolong the life of the pump and contribute significantly to the successful operation of your...

Page 25: ...ector be a minimum of 6 10 pipe diameters in length 3 The pipe used should be the same size as the inlet of the pump c The piping in the immediate vicinity of the pump must not be supported by the pum...

Page 26: ...Fulton Ltd about re sizing the orifice If the temperature of the cooling water is greater than 13 C to begin with a correspondingly greater flow rate is required d For automatic operation of water co...

Page 27: ...is expelled into the tank should not be reintroduced into the system 3 Ensure the vent from the catch tank is located and installed in such a manner as to protect personnel and property from discharg...

Page 28: ...ids and copper and aluminum act as catalysts in the degradation of some thermal fluids Carbon or stainless steel or ductile iron are recommended c Expansion joints or properly designed and sited loops...

Page 29: ...CHEMATIC j Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer k High point bleeds are to be installed at all high points in the system...

Page 30: ...all bolts to 20 final torque specification following a star pattern This means do not tighten bolts in order as a clock This will result in a poor seat between 12 o clock and 1 o clock 7 Tighten all b...

Page 31: ...7 Recommended Loads for JM Clipper elastograph 150 Gaskets SAE Grade 5 Bolts typical or Equal NOMINAL FLANGE SIZE INCHES NUMBER OF BOLTS DIAMETER OF BOLTS INCHES PREFERRED TORQUE REQUIRED PER BOLT FT...

Page 32: ...ndard gaskets supplied by Fulton for operating temperatures above 343 C are Flexitallic Spiral Wound Recommended Loads for flexitallic spiral wound 300 Gaskets SAE Grade 5 Bolts typical or Equal NOMIN...

Page 33: ...satisfy the materials and construction requirements described above 2 The type of operation and design of porting are governed by the degree of control required as well as the particular application l...

Page 34: ...es b Unlike steam or high pressure water systems thermal fluid attains extremely high temperatures without a corresponding increase in pressure While this lack of high pressure in the system yields ma...

Page 35: ...aximum fluid temperatures quoted are the actual limit to which any of the fluids may be subjected It is important to remember that in any fired heater there exists a film temperature which is higher t...

Page 36: ...thin the first two months after start up d During the first few months of operation sampling may be carried out at frequent intervals to confirm that system performance has been predicted correctly e...

Page 37: ...o confirm location of spool pieces etc as the flange stamps are shown on the drawing in hexagonal callouts The flange stamps should matched and aligned the flange stamps should be directly across from...

Page 38: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 30...

Page 39: ...gh point bleed through a pressure regulating valve Note Unless specially filtered compressed air will introduce moisture into the system Dry air or Nitrogen is recommended d Make sure that there are n...

Page 40: ...rum can easily explode creating a hazard to personnel and equipment FIG 16 DRAIN AND FILL CONNECTION Expansion Volume Vent for piping to Safe Catchment Expansion Tank Hot Fluid Medium Fluid Cool Fluid...

Page 41: ...ter fluid appears in the low level connection only a small amount of additional fluid should be required 4 If fluid is observed coming from the expansion section high level manual test connection drai...

Page 42: ...levated 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 filling Start the circulating pump as described under Cold...

Page 43: ...ait for flow to start If after two minutes flow has not started add more fluid as described above and run the pump for five minutes 5 Constantly check the bearing area located immediately behind the c...

Page 44: ...on with the specific procedure information detailed in the rest of Section 3 3 6 1 start up service a If start up service has been included in the order the factory should be contacted after the insta...

Page 45: ...switch back to Off immediately Change the wiring connections and recheck 9 Check for proper alignment Realign at temperature 10 With the control switch set to Pump push and hold the pump start button...

Page 46: ...e and welding slag will loosen and enter the fluid stream This will be trapped in the strainer causing vacuum at the pump suction This procedure must be followed as necessary in the course of heater o...

Page 47: ...eaks and tighten valve packings to the point of stopping leak 6 Upon putting unit back into operation check all gauge readings and compare to values given to you by the start up technician Note any di...

Page 48: ...fficient unstable or non existent pilot or main flame the flame sensor will cause a safety lockout of the flame programmer Safety lockout can also be caused if the flame sensor is improperly positione...

Page 49: ...l is turned off and the modulating motor 4 Units with Spark Ignition The spark and oil valves are energised and a timed trial for ignition begins With the flame proven the control advances through its...

Page 50: ...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 scann...

Page 51: ...bly from the burner 4 Install the oil nozzle assembly see Figure 18 and attach the oil whips to the assembly 5 Open all oil manual shutoff valves 6 Set the fuel selector switch to the proper fuel Rest...

Page 52: ...es to 44 Interv 1 6 The full listing of program stops are 24 Air damper in the prepurge position 32 Traveling to the FGR position 36 Ignition position before pilot ignition 44 Ignition position after...

Page 53: ...control The red light should go out 5 To change the setting return to the front menu by pressing Escape until you are to the main menu Then select Params Display RatioControl GasSettings SpecialPosit...

Page 54: ...o be stable and with clean combustion Exact setting is to be performed once high fire is confirmed 6 Press Escape 5 times to get back to the main menu 7 You can observe the status of the burner by goi...

Page 55: ...d 8 Repeat step 2 but start at the high fire point number Continually decrease the point number after combustion has been verified at each point 9 Once all the points have been verified press Escape u...

Page 56: ...screen 4 To return back to Auto operation repeat step 1 2 5 Please refer to this manual s addendum for information on specific LMV 51 control parameters Note DO NOT leave unit unattended in Manual Op...

Page 57: ...up Record readings in a log book and contact the Fulton service department immediately in the event of abnormal readings Failure to take action when fluid flow is reduced may result in serious and rap...

Page 58: ...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 a...

Page 59: ...al Fluid Heater Manual 12 2013 ISSUE 1 Page 51 3 FIG 22 ELECTRICAL PANEL Miniature Relays Control Circuit MCB Burner Control Terminals for External Connections Contactors Power Supply Protection Devic...

Page 60: ...3 9 2 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...

Page 61: ...ent of loss of flow 3 The differential pressure switch can be tested while only the pump is running at operating temperature Remove the metal cover on top of the switch and increase the setpoint until...

Page 62: ...hould correspond to the reading on the inlet pressure gauge 4 With the unit cold and pump running lower the high fluid pressure cutout switch until the pump shuts down Note the setpoint and raise by 1...

Page 63: ...some modification 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...

Page 64: ...outlet manifold The temperature setpoint in the controller may be adjusted per manufacturer s instructions 3 9 12 On off controls Typically one controller is provided to sense the temperature on the...

Page 65: ...ts on the flame safeguard pilot and main 5 With no flame established the flame safeguard will not receive a flame signal from the scanner 6 After 4 seconds the flame safeguard programmer will assume a...

Page 66: ...ioning of all system valves to ensure flow is not dead headed 2 Visually check relative position of minimum level float switch in the combination tank 3 Turn on power supply switches 4 Where applicabl...

Page 67: ...ith regular work gloves 4 With piping system at ambient temperature torque all bolts on the skid and throughout the system to the gasket manufacturer s specification using proper flange torquing pract...

Page 68: ...ton service department and at the end of this manual 2 Make a visual inspection of the entire system for leaks Make repairs as soon as possible 3 In systems utilising a water cooled thermal fluid circ...

Page 69: ...on checked for efficiency 5 Review daily log sheets noting any deviations from the norm 4 3 3 monthly IN ADDITION 1 Clean fuel filters 2 Check burner blower Clean if necessary 3 Clean or change air fi...

Page 70: ...service technician to perform annual preventative maintenance 4 4 1 TEMPERATURE LIMIT S Adjust the set point s of the temperature limit s down to a point lower than the PV process variable is typicall...

Page 71: ...switch Manually turn the liquid level switch cam anti clockwise The micro switch will open the contacts and control voltage will be lost Release the cam and the micro switch will make and control volt...

Page 72: ...pointer on the switch should be within 0 15 barg of the observed pressure Reset the switch to the original set point FIG 29 INLET AND OUTLET PRESSURE GAUGES FIG 30 HIGH OUTLET PRESSURE SWITCH High out...

Page 73: ...the pump causing the pump to fail 2 A Pump Suction gauge is provided on Fulton thermal fluid packages to help determine when a strainer needs cleaning Generally this point is between 0 and 0 17 barg 3...

Page 74: ...set for the desired set point and test for proper operation l High Outlet Pressure Switch 1 All C Model heaters have a High Outlet Pressure Switch This is a normally closed switch that opens with exc...

Page 75: ...ream of the heater will increase the pressure that the heater outlet sees This obstruction will generally result from an improper valve setting 2 Observe the heater outlet pressure at temperature with...

Page 76: ...e temperature of the thermal fluid Remove the strainer and clean with compressed air high pressure water or a cleaning solution Replace and observe new heater inlet pressure c Failed circulation pump...

Page 77: ...me rewiring and or reprogramming will be needed Contact Fulton service department if necessary 2 Temperature sensor failure a Different temperature controllers use different types of temperature senso...

Page 78: ...eset If this these switch es trips it is generally one of the following issues b Flow rate is too low 1 Too low of a flow rate will result in a higher rate of heat transfer to the thermal fluid and he...

Page 79: ...C Stack Temp C Nitrogen Level barg Pilot Flame Signal Run Flame Signal Visual Inspection of pipework for signs of leakage Actions Remarks Sig On Off On Off Y N On Off On Off Y N On Off On Off Y N On O...

Page 80: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 72...

Page 81: ...1273 1252 1252 1611 1791 2413 2753 2753 D Overall Depth 1173 1540 1540 1691 2046 2046 2237 2736 3432 3882 3882 E Overall Height 1872 2050 2046 2278 2556 2856 3648 3632 3721 3718 4144 F Heater Height 1...

Page 82: ...ectric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 74 5 B K H J E C F G H J D L A Model FT 0600 C A K H J E C F G H J D L B Models FT 0800 C and FT 1400 C B K H J E C F G H J D L A Models FT 1000...

Page 83: ...atural Gas On Off mbar 34 9 34 9 34 9 34 9 34 9 34 9 99 7 99 7 298 9 298 9 298 9 Min LPG mbar 34 9 34 9 34 9 34 9 34 9 34 9 99 7 99 7 298 9 298 9 298 9 Max mbar 345 345 345 345 345 345 345 345 Firing...

Page 84: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 76 5 5 3 electrical diagrams FIG 31 ELECTRICAL DIAGRAM FT C 0430 ELECTRICAL THERMAL FLUID HEATER ON OFF...

Page 85: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 77 5...

Page 86: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 78 5...

Page 87: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 79 5...

Page 88: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Page 80 5...

Page 89: ...eater When ordering spare safety valves it is important that as well as the information requested above the following additional information is given Heater design pressure given on the heater data pl...

Page 90: ...FT C Vertical Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1...

Page 91: ...ect Costs of carriage and of detaching and incorporating parts will be borne by you ln all cases at the termination of such 12 months all liability on our part will cease No liability whatsoever is to...

Page 92: ...cal Electric Thermal Fluid Heater Manual 12 2013 ISSUE 1 Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England Telephone 44 0 117 972 3322 Fax 44 0 117 972 3358 Email sales fulton co uk www fu...

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