Safety Precautions

To Owners, Operators or Maintenance Personnel: It Is essential to read and understand the following safety precautions before attempting to operate or service this equipment: Failure to heed these precautions may result in damage to equipment, serious personal injury or death! 1. The equipment should be operated only by personnel who have a working knowledge and understanding of the equipment. 2. A complete understanding of this equipments operational manual is required before attempting to startup, operate or maintain the equipment 3. Disconnect and lockout the main power supply in order to avoid the hazard of electrical shock. 4. Do not repeat unsuccessful lighting attempts without rechecking the burner and pilot adjustments. 5. The cause for loss of flame or any other unusual condition should be investigated and corrected before attempting to restart. 6. Should a starting failure occur for any reason, combustible fumes may fill the combustion chamber. Never attempt to re-light the burner under these conditions without first purging. 7. Do not re-light the pilot or attempt to start the main burner, either oil or gas, if the combustion chamber is hot and/or if gas or oil vapor combustion gases are present in the furnace or flue passages or when excess oil has accumulated. Promptly correct any conditions causing leakage. 8. When switching the fuel in dual fuel burner, stop the boiler first. Do not attempt to start the boiler when the combustion chamber is still hot. 9. Do not disassemble, maintain or change any boiler pressure parts when the boiler and its connecting piping is under pressure or hot. 10. When a leakage is found in gas piping (especially LPG gas), do not attempt to start, maintain or repair the boiler before correct the problem and confirmed by the local gas company. 11. When light the boiler, any person should stay away from the boiler. Standing in front and near the front and rear smoking chamber and burner is strictly restricted. Thank for choosing Fulton boilers! Fulton China 2011-1-13

Introduction
This manual presents information that will help to properly operate and care for your Fulton boiler, and the requirement should be followed in maintenance. These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards which may be applicable. Although every operation and control equipment may work reliably for a long time, necessary test should be done to avoid damage to equipment or personal injury or death. It is recommended that the daily, weekly, monthly and semi-annually, annually maintenance, and any abnormal status should all be recorded carefully so that service technician can easily determine and solve the problem. The requirements and instructions contained in these sections are mainly for the standard Fulton boiler model FBC/FBD. When installing a packaged unit, read entire sections to ensure that the installation is carried out correctly. Prior to shipment the following tests are made to assure the customer the highest standards of manufacturing: a) Material inspections. b) Manufacturing process inspections c) Welding inspection. d) Hydrostatic test inspection. e) Electrical components inspection. f) Operating test. g) Final engineering inspection. h) Crating inspection. The customer should examine the boiler for any damage, especially the refractory. Fulton boiler is constructed in accordance with Technical Supervision Regulation for Safety of Steam Boiler or ASME code. Regular inspection should be carried out by competent personnel with interval between two inspections no more than 14 months. The range and actual interval is decided by the competent personnel as detail. The operator should have been qualified with certificate and operate the boiler per corresponding regulations. Follow the requirement, otherwise boiler damage or serious personnel injury may result. Warnings The installer should ensure proper and safe connections that all the accessories to the boiler. Do not attempt to maintain your Fulton boiler without corresponding knowledge. Consult us in time for the related technique support. Fully understand the circuit prior to wire or remove one electric component. Wrong wiring may result severe situation. Do not operate boiler while status like trouble sets forth or part(s) is (are) lost, otherwise personnel injury or death may result. Ensure all the steps of maintenance are carried out before operation. Please follow the local regulations. Do not change fuel without written agreement from Fulton. Consult Fulton for reinstallation engineer of Fulton will arrange this. and the

Do not operate boiler overload due to boiler damage or dangerous situation.

Content
1 Description
General Specification

2 Installation
General Locating the boiler Vent Flue Outlet Water Supply Valves & Gauges Electric Requirement Gas Supply Oil Supply Check after Installation Boil Out for New

3 Control System & Burner

Controls Flame Programmer-RM7800 Relay Module Boiler Pressure Control Boiler Temperature Control IC-S/D Burner

4 Boiler/Burner Operation
Start up Boiler Shut Down Boiler Joint Inspection Burner Operation

5 Maintenance
Regular Check Recommend Daily Maintenance Recommend Week Maintenance Recommend Semi-Annual Maintenance Recommend Annual Maintenance Fitting New Gasket Burner Maintenance Common Gas Line Maintenance Flow Chart

6 Trouble shooting
Trouble shooting Honeywell RM7800 Trouble shooting

7 Guarantees
2

SECTION 1 DESCRIPTION
General

Fulton FBC/FBD series is a kind of horizontal, three or four pass wet back boiler constructed in accordance with ASME and/or Chinese code. In which FBC series are steam boilers while FBD series are hot water boilers. The packaged boiler is consisted of pressure vessel, burner, burner controls and appropriate boiler trims. Each boiler has been strictly inspected to guarantee the highest standards. However, high performance is achieved by following this manual at the aspect of installation, operation and maintenance. Smoke boxes are mounted at front and rear of the boiler for convenience of cleaning the combustion chamber. There is a manhole at the top of boiler, while hand holes are located at side bottom, front and rear of the boiler for PV check. The following are standard fittings and accessories: Steam boiler 1 Main Steam Valve 2 Safety Valve 3 Blow Down Valve 4 Surface Blow Down
2

5 Water Gauge Assembly 6 Steam Pressure Gauge Assembly 7 Water Feed Valve & Check Valve 8 Water & Steam Pressure Control Hot Water Boiler 1 Main Water Supply Valve (optional) 2 Return Water Valve (optional) 3 Safety Valve 4 Exhaust Valve 5 Blow Down Valve 6 Low Water Protect 7 Temperature Protect and Control 8 Limit Temperature Interlock

Specification
FB-C Boiler Specification

Note1. The above feed water pump is the standard Fulton pump, other please consult factory. 2.All steam output rating from 0PSI at 212oF, fuel consumption based on light oil 20,160 Btu/lb (11200 KCal/kg), heavy oil 19728 Btu/lb (10960KCal/kg), natural gas 1,000 Btu/ft3 (8900KCal/m3). 3. Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. the factorys most current drawings. Please refer to

FB-C Boiler Exterior Dimension

Note: 1. The above number is based on light oil burner. 2. Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. Please refer to the factorys most current drawings.

FB-C Boiler Connection

Note: 1.Electric requirement is based on the standard fittings. 2.Shipping weight doesnt include the burner system. 3.Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. factorys most current drawings. Please refer to the

FB-D Hot Water Boiler Specification

Note1. Fuel consumption based on light oil 20,160 Btu/lb (11200 KCal/kg), heavy oil 19728 Btu/lb (10960KCal/kg), natural gas 1,000 Btu/ft3 (8900KCal/m3). 2. Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. Please refer to the factorys most current drawings.

FB-D Hot Water Boiler Exterior Dimension

1. Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. Please refer to the factorys most current drawings.

We supply other options as users requirement. Fulton FBC/FBD boiler may be fit with oil (light oil or heavy oil), gas, and dual fuel full modulation burner.

SECTION 2 INSTALLATION
General
Only proper and trained personnel should install Fulton FBC/FBD boiler, and the installation should comply with all the relative safety specifications and local regulations. and local regulations. b. Sufficient space around the boiler should be available in the boiler room for ease access to all the boiler parts for boiler operation and maintenance. c. The boiler should be placed on a level floor with firm base and without combustible articles surrounded.

Locating the boiler

a. The boiler room should be arranged in accordance with the relative safety specifications

Fig. 2-1 Boiler room Lay Out (Reference)

Vent
a. Proper ventilation of the boiler room is essential. It requires one opening of fresh air for 6.4cm2 for every 756 Kcal. Table 2-1 Recommended Min. Air Opening Model FB-C Minimum area (m )
2

b. Provide both high and low level openings per burner power for safe and efficient boiler operation.

300 3.1

350 3.6

400 4.2

500 4.8

650 6.2

800 7.2

1000 9.1

1300 12.4

Flue Outlet
The height and type of flue will be subject to local specifications. Where a flue is required by multi-boiler are necessary, ensure the common section meets the requirement that all boilers can work at the same time, and special design must be obtained. a. The diameter of chimney must be not less than that of flue outlet; otherwise the increased gas resistance would affect combustion. b. Usual chimney arrangement supply -0.02~-0.04 w.c. pressure. However, the pressure should not be too much. Install regulator at the flue outlet while the pressure is too much due to construction etc. c. Avoid fitting 90o elbows and long distance horizontal runs. The total horizontal runs should not exceed 25% of the vertical rise. All horizontal runs should have a rising pitch of 15o minimum to lower resistance and prevent condensate from building up and subsequent corrosion. d. Oil-fired boiler installation is generally more critical because of the sulphur content in the fuel and the dew-point temperature. Specialist advice should be obtained on flue and insulation. e. Flue outlet should higher than all the roofs around the radius of 10m. f. Check boiler smoke outlet, flue and each joint of chimney for sealing.

10

11

Fig. 2-2

Chimney Arrangement

12

Fig. 2-3

Heating System Arrangement (Reference)

Water Supply
a. Feed water contains solids and dissolved gases. High dissolved oxygen and chloride levels, low PH and high water hardness can all be major causes of corrosion and deposition. These may influence boiler life. So, water treatment is necessary. b. Fit water softener equipment while water hardness is high. c. The dissolved oxygen can cause corrosion in boiler plate and water supply system, with many pits. These little pits gradually change into larger ones and usually covered by ferric oxide. Once the corrosion sets forth, the speed will be rapid without reverse. One way to reduce the dissolved oxygen is to heat feed water to let air escape. Inject steam into the water to raise the temperature to 82oC so that the dissolved oxygen is removed from the water. It is recommended to install oxygen removing equipment. d. Feed water should be studied individually and treated accordingly by reputable professionals in this field. It is highly recommended that a water treatment specialist is consulted prior to install the boiler. e. The Fulton Warranty does not cover damage or failure that can be attributed to corrosion, scale or dirt accumulations. Oxygen is corrosive.

Table 2-3 Water Requirement Item Rated Capacity Mpa Suspend solids mg/L
Total Hardness mmol/L Total Hardness mmol/L
1

Feed Water 1.0 5

W/O Superheater W/ Superheater

Boiler Water 1.0 ~ 10~12 4000 1.0 1.6 ~ 14 10~12 3500 3000 10-30 10-30 0.2 1.6 2.5 ~ 12 10~12 3000 2500 10-30 10-30 0.2

1.0 1.6 5 0.03 7 0.1 2 0.3

1.6 2.5 5 0.03 7 0.05 2 0.3

0.03 7 0.1 2 0.3

PH25 Dissolved Oxygen mg L3

W/O Dissolved Solids mg L
4

Superheater W/ Superheater

So32-,

mg/L

PO43-, mg/L
Relative Alkalinity(Free NaOH /Dissolved 5 solids

Oxygen mg/L Fe mg/L6

a. It is recommended that blow down every day to avoid corrosion and scale inside because of the solids and concentrate salt deposit in the boiler. b. It is recommended to heat feed water in case of no condensation water.

13

Valves & Gauges

The boiler pressure fitting is mounted at the upper right side, with one three way cock faucet downstream the pressure gauge for periodical blow down. Main steam Valve/Water Supply Valve Distribution pipeline should be run from the main steam valve or water supply valve on top of the boiler to the steam or hot water delivery point. Adequate condensate drainage and expansion facilities are provided with the pipeline. Securely support the valve to avoid excessive load. Blow Down Valve The boiler is fitted with two or three blow down valves. One is at each water gauge and the main at the side of front and rear of the boiler. Pipeline from these valves must be connected to a receptacle of approved with all process follow the local regulations. Safety Valves The safety valve is factory fitted at the top of boiler and preset. Do not adjust without permitting from authority and Fulton. a. The Fit pressure is indicated on the valve. Do not adjust without permitting from authority and Fulton. b. This valve is designed to prevent the boiler from exceeding its design pressure. c. Any system connected to the boiler which is not capable of accepting boiler pressure must be protected by a separate safety valve setting to the required pressure. d. It is recommended to fit the discharge pipe with size equal or more than safety valve outlet. The discharge pipe should be capable of strength bearing, and as short as possible. The discharge outlet should be piped to a safe discharge point and the condensate will drain away easily. (Do not connect blow down pipe). Caution: The factory-fitted safety valve is designed to protect only the boiler. This valve must not be used to protect other items.
14

Water Gauge Assembly FBC steam boiler is fitted with two plate water gauge assemblies. The water gauge blow down valve is connected to the auxiliary blow down line by 1/4soft copper tubing. Water Sample Valve (Surface blow down) The standard fitting is at the right side of the boiler that makes water sample to control boiler water. Water Feed Valve/Check Valve The Water feed valve is connected to the water inlet which at middle right side of boiler. The check valve is fitted at the end of the line of water feed valve to prevent return water. Return Water Valve Installed at the top return water inlet for system hot return water using.

Electrical Requirement
The boiler wiring diagram is located on the inside of the boiler control panel. A 3-phase 5 wire supply is required; the power is 380V/50HZ/3phase. Voltage limit: high and low 10%. Caution: all electrical work should be undertaken by a qualified installer according to local regulations.

Gas Supply
Natural gas is the standard for the gas boiler. If special requirements i.e. liquid petroleum gas, town gas or others are used, consult Fulton prior to use. The gas pressure varies with different burner models and burner head. Outer pipeline should be greater one to keep enough operation gas pressure (dynamic).Verify if the gas pressure meets the requirement of the burner, install one gas booster in case of too low pressure. Any question please consults FULTON When a gas booster is used, the gas pressure at the booster inlet must not fall below 1000 mm W.C.. The booster should be installed as near as

possible to the burner. It should be positioned on a firm, flat, horizontal surface using anti-vibration mountings. All connecting pipework should be well supported and accurately positioned in order to avoid stressing the booster casting. The use of flexible connections, which reduce both pipework stresses and transmitted noise, is strongly recommended. The gas supplier should be asked to recommend the size of pipework between the meter and the booster to ensure that the required pressure and flow are available. To minmize gas pressure drops, eliminate all unnecessary elbows and bends between gas meter and head. Install one correct size gas valve as close as possible to the head. One butterfly gas stop valve with interlock switch is mounted on the dual burner. The switch should be connected to the interlock terminal inside the control panel. The gas supply pipework to the boiler must be appropriate to local conditions and must be constructed and installed in compliance with appropriate Codes and Standards, and must be undertaken by qualified professional personnel.

NOTE: It is essential that a manual isolation valve is fitted upstream of the gas control train to allow the burner to be isolated for maintenance. The size of this valve should not be less than that of the burner control train in order to avoid any restriction in gas flow. WARNING: It is essential that the installation of the gas pipework must be undertaken only by suitably qualified and experienced personnel and in compliance with appropriate Codes and Standards.

Oil Supply
Oilfired boilers are supplied with a matched automatic modulating oil burner suitable for use of light diesel oil. The oil is 0# with storage temperature not less than 5oC and heat is required for heavy oil to obtain good flow. Other fuels consult Fulton. The pipework should be seamless steel tube, zincification is not permitted. Heavy Oil supply requires heater and the oil storage tank as well. The recommended heat Temp. is as follows:

Table 2-4 recommended heat Temp. Item 1 2 3 4 5 6 Two-pipe System A two-pipe system must be used between oil storage tank and the burner. One for oil supply and one for oil return. A circulating oil pump is required to deliver fuel oil from the storage tank to the burner. Circulation pressure is 15psi while 50-70 psi is for FBC1300 models and above.
15

Oil 20#-60# 80#-120# 180# 200# 220# 250#

Oil Tank Heat Temperature 40-60 50-70 60-80 70-90 80-100 90-110

Burner Electrical Heat Temperature 50-70 60-80 70-90 80-100 90-110 100-120

An oil filter must be installed before the oil circulating pump, recommend below 2t/h more than 80 mesh/inch2 and above 2t/h more than 60 Mesh. Use flexible pipework for the final oil connections

to the oil pump (stainless steel corrugation tube). Ensure no twist generates and the sealing is good. One stop valve should be installed at the inlet and outlet of the circulating pump separately. A pressure gauge (0-60psi) is needed also to the outlet. Oil supply pipework use DN50 seamless steel tube to reduce pressure loss.

It is important to ensure that the return pipe is not obstructed or closed suddenly, install stop valve as little as possible. In case of heavy oil 4#, 5#, and 6# oil (heavy oil 80#~250#) the pipework and oil storage tank should be with heater. Fig 2-3 Two Pipe System

Check after Installation

Check for all pipework connection, remove dirt in pipework and check for leakage. Check for pressure control. Check for control panel and other circuit connection per requirement. Impurity among combustion air would damage the steel jacket and firetube if the door of boiler room is closed. Note : After complete the installation, Clean the PV prior to operation.

Boil out for New

Clean the pressure vessel of any oil film, dirt, or other impurities that set forth in the process of production to avoid heat efficiency loss. Boil out a new boiler is one of the cleaning methods. Boiler installation unit should know the method and may be the agent to do this. Many chemical medicines may be used for boiler out, usually apply mixture of trisodium phosphate and sodium hydroxide with water with percentage 0.3%~0.5%, and add a little wash detergent too. Recommended steps: a. Prepare chemical medicine. b. Prior to dissolve the medicine, pour warm water into suitable vessel carefully, then slowly put the medicine, then mix continuously up to uniform solution.
16

c. Install one overflow pipe at any opening on top of the boiler and discharge to safe place. d. Remove the safety valve to avoid oil adhering to it. e. Close all the valves connected to the system to prevent detergent entering into system. f. Pour clean water up to top end of water feed pipe. Fill the above solution into the boiler. The water temperature should be the same as ambient. g. Heat the boiler with low fire to keep boiler water boiling. The time of boil out should be no less than 5 hours with no steam pressure generating. h. At this moment, fill the boiler with a little water to bring away the impurities via overflow. j. Continue the boil out and overflow until overflow is clean and PH less than 9, then shut down the

burner. k. Let the boiler Temp. drop to below 48oc. l. Remove handholes, applying high pressure water to wash the gasket surface. m. Check the inside of PV, boil out again in case there still is dirt existing. n. Replace handholes and safety valves. Heat the water above 83oc to relieve dissolved oxygen. o. Prevent corrosion inside the boiler.

If the boiler has been already used or surely the inside is clean, the above can be done per detail. Besides, caution should be taken to prevent the impurities from the boiler system come into the boiler. In the steam boiler system, the condensate water should be abandoned if the impurities in the condensation system can not be cleaned. And ensure the makeup water quality to prevent impurities. Drain the steam return water in the first week to clean dirt in main steam pipe and condensate return tube.

17

SECTION 3 CONTROL SYSTEM & BURNER

Boiler controls, indicators and switches are mounted in the control panel on the side of the boiler. There are green, yellow and red indicators, green and yellow show the present status, red shows trouble. While the red light usually with the alarm sounds which needs special care. The follows are standard control panel; refer to the detail label on control panel and wiring diagram for applicable special specification with different arrangement. Fig. 3-1 Control Panels

FBC300-650 Steam Boiler Control Panel

18

15 1 2 3

10

12

11

13

14

FBC300-650 Gas Fired Steam Boiler Control Panel Inner View

19

21

10

12

14

16

18

11

13

15

17

19

FBC300-650 Light Oil Fired Steam Boiler Control Panel Inner View

20

22

10

12

14

16

17

19

11

13

15

18

20

21

FBC300-650 Heavy Oil/Light Oil Fired Steam Boiler Control Panel Inner View

21

21

1 2 3

10

12

14

16

18

11

13

15

17

19

FBC300-650 Light Oil/Gas Fired Steam Boiler Control Panel Inner View

22

22

1 2 3

10

12

14

16

17

19

11

13

15

18

20

FBC300-650 Heavy Oil/Gas Fired Steam Boiler Control Panel Inner View

23

FBC800-1300 Steam Boiler Control Panel

24

12

10

11

FBC800-1300 Gas Fired Steam Boiler Control Panel Inner View

25

16

10

11

12

14

13

FBC800-1300 Light Oil Fired Steam Boiler Control Panel Inner View

26

17

10

11

12

13

14

15

FBC800-1300 Heavy Oil/Light Oil/Gas Fired Steam Boiler Control Panel Inner View

27

17

10

11

12

13

15

14

FBC800-1300 Light Oil/Heavy Oil Fired Steam Boiler Control Panel Inner View
28

16

10

11

12

13

14

FBC800-1300 Light Oil/Gas Fired Steam Boiler Control Panel Inner View

29

12 1 2 3

Alarm

Air Switch

Fuse

Transformer

Control Transformer

Water Relay

Control Relay

9
Blower Motor AC Contactor

Flame Programmer

10

Blower Motor Overload Protector

Terminal

11

30

Alarm
Power

Low Water

Flame Failure

Extra Temp.

Green

Red

Red Ignition

Flame Automatic Flame Manual

Red Main Fuel Valve Open

Yellow

Yellow

Yellow

Yellow

Working Temp. Control

Limit Temp. Control

PUSH

Boiler Control ON OFF

Manual Firing Rate

Limit Low Water Reset

Firing Rate AUTO MANUAL

Alarm Cancel

Urgent Stop

FBD Gas Fired Hot Water Boiler

31

19

Alarm

Air Switch

Fuse
6

Transformer

Control Transformer
5 7

Lower Water Relay

Flame Programmer
8 10 12 14

Control Relay

11

13

15

18 Terminal

8-9 Metering Pump Fan AC contactor,Heat Overload Protector 10-11 Circulating Oil Pump AC Contactor,Heat Overload Protector 12-13 Compressor AC Contactor, Heat Overload Protector 14-15 Blower Motor AC Contactor, Heat Overload Protector

32

Alarm
Power

Low Water

Flame Failure

Extra Temp.

Green

Red

Red Ignition

Flame Automatic Flame Manual

Red Main Fuel Valve Open

Yellow

Yellow

Yellow

Yellow

Working Temp. Control

Limit Temp. Control

PUSH

Boiler Control ON OFF

Manual Firing Rate

Limit Low Water Reset

Firing Rate AUTO MANUAL

Alarm Cancel

Urgent Stop

FBD Light Oil Fired Hot Water Boiler

33

20

4 3

Alarm

Air Switch

Fuse
6

Transformer

Control Transformer

Lower Water Relay

Flame Programmer
8 10 12 14

Control Relay

15

11

13

Heavy Oil Heater(heavy oil)

16

19 Terminal

8-9 Metering Pump Fan AC contactor,Heat Overload Protector 10-11 Circulating Oil Pump AC Contactor,Heat Overload Protector 12-13 Compressor AC Contactor, Heat Overload Protector 14 Three Phase Electrical Heating AC Contactor 15-16 Blower Motor AC Contactor, Heat Overload Protector

34

Alarm
Power

Low Water

Flame Failure

Extra Temp.

Green

Red

Red Ignition

Flame Automatic Flame Manual

Red Main Fuel Valve Open

Yellow

Yellow

Yellow

Yellow

Working Temp. Control

Limit Temp. Control

PUSH

Boiler Control OFF ON

Manual Firing Rate

Firing Rate AUTO MANUAL

Alarm Cancel

Limit Low Water Reset

Fuel Heavy Light Oil Oil

Urgent Stop

FBD Heavy Oil/Light Oil Fired Hot Water Boiler

35

17 1 2 3

Alarm

Air Switch

Fuse
6

Transformer

Control Transformer

Lower Water Relay

Flame Programmer
8 10 12 14

Control Relay

11

13

15

Terminal 16

8-9 Metering Pump Fan AC contactor,Heat Overload Protector 10-11 Circulating Oil Pump AC Contactor,Heat Overload Protector 12-13 Compressor AC Contactor, Heat Overload Protector 14-15 Blower Motor AC Contactor, Heat Overload Protector

36

Alarm
Power

Low Water

Flame Failure

Extra Temp.

Green

Red

Red Ignition

Flame Automatic Flame Manual

Red Main Fuel Valve Open

Yellow

Yellow

Yellow

Yellow

Working Temp. Control

Limit Temp. Control

PUSH

Boiler Control OFF ON

Manual Firing Rate

Firing Rate AUTO MANUAL

Alarm Cancel

Limit Low Water Reset

Fuel Light Gas Oil

Urgent Stop

FBD Light Oil /Gas Fired Hot Water Boiler

37

18 1 2 3

Alarm

Air Switch

Fuse

Transformer

Control Transformer

6 5 7

Lower Water Relay

Flame Programmer
8 10 12 14

Control Relay

15

11

13

Heavy Oil Heater(heavy oil)

16

Terminal 17

8-9 Metering Pump Fan AC contactor,Heat Overload Protector 10-11 Circulating Oil Pump AC Contactor,Heat Overload Protector 12-13 Compressor AC Contactor, Heat Overload Protector 14 Three Phase Electrical Heating AC Contactor 15-16 Blower Motor AC Contactor, Heat Overload Protector

38

Power

Low Water

Flame Failure

Extra Temp.

Green

Red

Red Ignition

Flame Automatic Flame Manual

Red Main Fuel Valve Open

Yellow

Yellow

Yellow

Yellow

Working Temp. Control

Limit Temp. Control

PUSH

Boiler Control ON OFF

Manual Firing Rate

Firing Rate AUTO MANUAL

Alarm Cancel

Limit Low Water Fuel Reset Heavy Light

Gas

Urgent Stop

FBD Heavy Oil/Gas Fired Hot Water Boiler

39

Controls
a. Power Indicator (green) Indicates power is on. b. Boiler Operation Indicator (green) shuts off. i. Boiler Control Switch off/on Turn this switch to the right, boiler starts up and the green indicator in the control panel lights; the burner programmer starts the pre-ignition purge and detection. As the programmer enters into normal operation, the flame detector will monitor combustion flame all the time, and boiler begins normal operation. If any abnormal is detected by the programmer, the burner would cut out automatically. After burner blower stopped, push the reset button in the programmer, the programmer will auto reset. j. Fire regulator manual/auto

Indicates boiler is in normal operation. c. Ignition Indicator (yellow) Indicates ignition solenoid valve is open. d. Main Fuel Valve on (yellow) Indicates burner main fuel solenoid valve with PID regulation open; the burner is in percent regulation status. e. 2nd Low limit water indicator (red) Steam boiler has low water interlock function. When the boiler water level drops below 1st low water probe, burner auto shuts off. Only after the boiler water level returns to the safe working level, burner would auto start again. The 2nd low water relay alarm sounds and indicator ignites if the boiler water level is below 2nd low water limit probe; and the burner continues to shut off. Only after the boiler water level return to normal (about the middle of the water gauge glass) and water relay is manually reset, the burner may auto start again. Warning: After the 2nd low water alarm sounds, burner starts only after feed water pump works and the water level return to the normal level. f. High water Indicator (red)

Turn the switch to right, fire will be adjusted automatically according to steam pressure. While in manual position, fire can be controlled by the manual adjust switch in the control panel. k. Manual firing rate regulator Control the burner fire manually while fire regulator manual/auto switch in manual position. When in auto position, manual adjust does not function. l. Pump manual/off/auto

It will light while the boiler water exceeds the preset high water level and the alarm will sound. Water feed pump will stop until the water level falls to normal. Alarm will cancel and light will extinguish after back to the normal water level. g. Flame failure (red) The lamp will light, alarm will sound and burner will cut off when flame failure. h. High steam pressure (red) When boiler steam pressure exceeds preset level, the indicator lights and alarm sounds, and burner
40

Switch to manual position while fill the boiler. At this time, the boiler water will not be controlled by water relay. Water level will continuously keep rising for hydrostatic test etc. boiler inspections; Switch to auto position, water relay will automatically shut off pump while boiler water level reaches the normal position. m. 2nd low water reset The 2nd water relay works together with 2nd low water probe mounted in boiler. While water is below 2nd low, burner will be shut off and an alarm will sound. The pump feeds water continuously at that time until water is restored to normal, reset 2nd low water relay, then burner will start. n. Alarm Silencer The alarm will sound while boiler is in trouble to

notify personnel to check the problem. alarm can be manually canceled. o. Extra high pressure reset

The

whatever ignition or normal operations will lockout the programmer and the fuel electrical solenoid valve is shut at the same time to stop fuel supply. Mounting RM7800 Relay Module 1. Mount the RM7800 vertically on the Q7800 sub base, or mount horizontally with the knife blade terminals pointing downward. When mounted on the Q7800A, the Rm7800 must be in an electrical enclosure. 2. When mounting in an electrical enclosure, provide adequate clearance for servicing, installation and removal of the RM7800, keyboard display module, flame amplifier, flame amplifier signal voltage probes, electrical signal voltage probes, and electrical connections. a. Allow an additional two inches below the RM7800 for the flame amplifier mounting. b. Allow an optional three inch minimum to both sides of the RM7800 for electrical signal voltage probes. 3. Make sure no sub base wiring is projecting beyond the terminal blocks. Tuck in wiring against the back of the sub base so it does not interface with knife blade terminals or bifurcated contacts. Important The RM7800 must be installed with a plug-in motion rather than a hinge action. 4. Mount the RM7800 by aligning the four L-shaped corner guides and knife blade terminals with the bifurcated contacts on the wiring sub base and securely tighten the two screws without deforming the plastic.

The indicator will light while steam pressure exceeds preset and alarm sounds to notify related personnel, the burner will automatically shut down. Only after steam pressure drops to safe level, reset manually and then the burner continues to work again. p. Emergency stop push button Stop the boiler by pushing the emergency stop button while the boiler is in unpredictable trouble. q. High low water relay & pump relay These relays work together with water probes mounted in the boiler to control boiler water in normal ranges automatically. If water level is too low, burner will be shut off to sound the alarm. Water probes are mounted in two horizontally located probe bases at the top of the boiler. The standard FBC has its 2nd low water probe in left probe base. Boilers with high water alarm will sound to notify personnel to take actions to lower water level while water in boiler exceeds the preset high level. In this time, the burner will continue working. Consult Fulton if you want to shut down burner when water level reaches the high preset level.

Flame Module

Programmer-RM7800

Relay

The programmer monitors burner ignition and combustion cooperating with each sensor element per specified procedure; verify excellent flame and detect formed flame. Any abnormal

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Fig 3-2 RM7800 Module Explode View

Flame Establishing Period Model Initiate Standby Purge Pilot Maina Run Post purge Timing Interlock Circuit Firing Rate Circuit Energy Saving Prepurge Approval Code Bodies

Preignition, RM7800L 10S * ** 4 or 10S 10 or 15S

b

15S

Lockout, High and Low Fire

4-wire modulating

No.

FM/IRI Modulati ng

*Standby and Run can be an infinite time period.

**Purge determined by which ST7800A purge card is selected.

a The MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added.
b RM7800L105310 seconds or intermittent.

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Fig 3-3 RM7800 Wiring and Program Control

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Boiler Pressure Control

a. Working Pressure Control It controls burner operation and on/off. Shut down burner while pressure reaches preset and start burner while pressure drops to preset difference. c. Limit Pressure Control In case working pressure control switch failure, the boiler pressure will exceed preset limit which activates Limit pressure control (the setting exceeds at least 50kpa than that of working pressure switch) to shut down and lockout the burner, and the high pressure indicator will light. d. Modulation Pressure control With automatic burner firing rate percent modulation, reduce the firing rate automatically while boiler steam pressure gradually reaches upper limit of preset; and increase the firing rate automatically while boiler steam pressure gradually reaches lower limit of preset to raise the steam pressure. So the steam pressure is maintained at about preset level by firing rate percent modulation.

b. Working temperature control One temperature set for this purpose: 1. When boiler is in normal combustion, water temperature will rise till the set temperature, then the temperature control provides program signal to cut off all the fuel valve and stop burner. (Two situations are listed below) 2. When boiler temperature falls to one certain data that lower than working temperature in one period of time (the interior setting may be modified), the burner would re-start, then the boiler load is controlled by high/low fire temperature transformer. The boiler is controlled to normal operation as above. When boiler does not shut down as the temperature is at the set working temperature (shows working temperature control is in failure that need repair.), and the water temperature is raised up to high limit, the temperature will provide burning program signal to cut off all the fuel valves and stop burner with alarm, and at that time, the user should check for the working temperature control as interlock explained above. c. High limit temperature interlocks control One temperature set for this purpose: When boiler water temperature is raised to set working temperature but not stop boiler yet (shows failed working temperature which need repair). When temperature is raised up to high limit, the high limit temperature will provide signal to burner program to cut off all the fuel valves and stop burner with alarm. The user should check for working pressure control and temperature sensor.(Please consult a qualified technician as quick as possible.)

Boiler Temperature Control

a. High/Low Fire Temperature Control One temperature set for this purpose: While boiler is started in normal combustion, the control provides signal to burner which calls for high load operation of the boiler. When the temperature is raised close to the setting, the control provides signal to burner in-phase which calls for low load operation of the boiler. That is, to realize flame ratio control against temperature changes.

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Burner IC D/Series & S/Series

Introduction

Fig 3-4 D series burner a. General D series burner is for use with FBC-1000/ FBD-10.5(inc.FBC-1000) and below. S series burner is for use with FBC-1300 /FBD-10.5 and above. The burner is assembled, wired and tested output. The operator must be familiar with the individual functioning of all controls to understand the operations and procedures described in the manual. Identify and locate each item in the illustrations as they are described in the following sections. b. Description

Fig 3-5 S series burner settings for the starter, the rest of the control panel components require little attention except for occasional cleaning. c. Combustion Air Handling System D/series The combustion air handling system consists of three major components:

The industrial Combustion D/S series oil burners are of the low pressure, air atomizing (nozzle) type. Gas burners are of the periopheral mix type. All burners feature ignition by spark-ignited gas pilot flame. With either fuel, the burner operates with full modulation. A switch permits changeover from automatic fully modulated firing to manually set firing at any desired rate between minimum and maximum. Additional safeguards assure that the burner always returns to minimum firing position for ignition. The burner is designed for automatic, unattended operation except for periodic inspection and maintenance. After selecting the proper overload
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Fig 3-6 D Series Burner 1. Damper Assembly A rotary damper regulates the combustion air volume and is positioned by a modulating motor. The damper is normally ALMOST CLOSED in the low fire position and opens as the burner drives towards a high position.

2. Motor Driven Impeller The diameter of the impeller determines available air pressure and the width determines air capacity in cubic feet per minute. Alternate motor-impeller combinations are available for 50 cycle or 60 cycle power and for firing against either moderate or high furnace pressure. At attitude up to 2000ft. above sea level, model S impellers are recommended for up to 1.5 W.C. Model p impellers are recommended for furnace pressure from 1.5-4 W.C. furnace pressure. For higher altitudes and higher furnace pressures, motor and impeller combinations are determined at the factory. 3. Stator cone The stator cone in the air housing transforms the rotating air velocity pressure to static pressure prior to air entry into the blast tube. S series 1. Damper Assembly A multi blade system regulates the combustion air volume and is positioned by a modulating motor. The dampers are normally ALMOST CLOSED in the high fire position. 2. Motor Driven Impeller The diameter of the impeller determines air capacity in cubic feet per minute. Alternate motor-impeller combinations are available for 50

cycle or 60 cycle power and for firing against either moderate or high furnace pressure. For higher altitudes and higher furnace pressure, motor and impeller combinations are determined at the factory. d. Firing Rate Controls Regardless of the fuel used, burner input is fully modulated between low fire and high fire on boiler demand. Firing rate is controlled by the potentiometer-regulated modulating motor. Combustion air control damper, oil metering valve and/or gas volume butterfly valves are through variable rate and lever linkages. The modulating motor rotates 90 degrees from low to high position. Flow rate through each component is adjusted by positioning the control rods on the levers and the angular position of levers on shafts. Lever on the modulating motor shafts actuate the high fire position proving switch. e. Firing Head Access to the firing head is provided by swinging open the impeller housing. First, disconnect the damper linkage, release the housing latch and swing the housing to open position. An internal gas pilot is standard on all burners. Pilot gas pressure is adjusted at the pilot pressure regulator.

FIG. 3-7 D Series Firing Head

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Fig. 3-8 S Series Firing Head f. Oil System Air Atomizing mixes with fuel oil. Air/oil passes through grooves and out of the nozzle orifice in a cone of atomized oil. Proper velocity and angle of the fine spray ensures good mixing with the combustion air, providing quiet starts and excellent combustion efficiency. Nozzle Line Electric Heater (D Series) Provides heat for No.4, 5 and 6 fuel oil for cold starts and is located between the metering pump and 3-way valve. This heater should not be used as a continuous run line heater. Heater has an adjustable thermostat and a cold oil lockout switch which prevents burner from starting until proper atomizing temperature is attained. Oil Strainer Prevent foreign matter from entering the burner oil system. Atomizing Air Proving Switch Pressure actuated switch contacts close when sufficient atomizing air pressure is present. The oil valve will not open unless switch contacts are closed. Separate Compressor Module All Models (used with FBC series) have a burner mounted oil metering unit and a separate compressor module. The system functions as follows: Air Compressor Module

The burner compressed air for atomization. Atomizing air is independent of combustion air. The system is supplied with a separate compressor module for mounting near the burner. Depending on burner size and fuel, one system for model DL, DM, DLG, DMG No.2 through 5 oil with air atomization (model D42 to 145) uses an integral air compressor/oil metering unit mounted on the burner and is driven by a separate motor. 3-way Solenoid Valve Metered oil enters the common port of the 3-way solenoid valve. During shutdown, pre and post purge the valve is de-energized (N.C. port closed) and all metered fuel oil return to the storage tank. When the valve is energized, metered oil is directed to the nozzle through the N.C. port. Nozzle Assembly The nozzle assembly consists of four main parts: body, compression spring, swirler, and tip. The swirler is held against the nozzle tip by the compression spring. The nozzle body has inlet ports for air and oil lines. Metered fuel oil enters the nozzle body and flows the core of the swirler to the side parts where it meets with the atomizing air. Atomizing air enters and passes through the nozzle body to grooves in the swirler, where it

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Air is supplied by a positive displacement rotary vane compressor. This provides a constant volume of atomizing air regardless of pressure. The compressor module includes air-oil reservoir tank, air filter and the lube oil cooling oil. Air enters the compressor through the filter. The air flows from the compressed air. T he tank air pressure forces lubricating oil from the tank to the compressor to lubricate bearings and vanes. A sight glass indicates the level of lubricating oil in the air/oil reservoir. Lubricating oil must be visible in the gauge glass at all times. Air compression heat is absorbed in part by the flow of lube oil, creating a hot oil mist. The air/oil mist is cooled by a coil assembly. Lube oil is also cooled before entering the compressor. Oil Metering S series The oil metering unit is a MAXON Synchro flow control valve. The multiple screw cam assembly provides mechanical adjusting capabilities to the fuel ratio at each valve position throughout entire capacity range. Fig 3-9 Oil Piping Assembly

D series Integral Unit Fuel oil under nominal pressure in the circulating loop, flows to the adjustable positive displacement, (volumetric) metering unit. Oil metering is accomplished by changing the piston stroke by means of an eccentric shaft and pin assembly. Fig. 3-10 Integral Oil-air System and Tank

The pistons reciprocate in a rotor assembly, turning in a hardened steel sleeve having oil inlet and discharge slots. During each revolution the pistons go through the following cycle: 1 inlet cycle: The piston is at the bottom dead center position. At this position, the cavity between the top of the piston and the outside diameter of the to fills with oil. 2 Discharge Cycle: The piston is at the top of dead center position. At this position, the oil is forced out of the discharge port to the nozzle. The piston stroke length is determined by the position of the eccentric shaft and plate. The piston adjustment plate is positioned by an adjustable eccentric shaft. The eccentric shaft is positioned by the modulator through adjustable linkage. Counterclockwise rotation of the eccentric shaft increases the piston stroke (more oil delivered to nozzle); clockwise rotation decreases the amount of oil delivered.

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When the eccentric shaft is stationary, at any position, the stroke of the pistons remains constant delivering a constant volume of oil regardless of viscosity. Separate Unit The oil metering unit is cored with channels through the housing. Fuel oil circulates through these channels keeping the metering unit warm to prevent heavy oils from congealing when the burner is idle.

For the description of typical fuel oil piping installations, see section 2. Air enters a rotary vane compressor through an air cleaner where it is compressed to atomizing pressure. Air flows from the compressor to an air/oil tank which serves the multiple purposes of dampening air pulsation, lube oil mist recovery, lube oil and atomizing air storage. The compressor rotor is cooled and lubricated continuously by oil under pressure from the air/oil tank. Oil vapor is extracted by a mist eliminator in the upper section of the tank. Atomizing air from the upper tank section is delivered to the nozzle at a constant volume. Air pressure increases as the burner firing rate increases. Atomizing pressure may be adjusted by the needle valve located on the air-oil pump. The valve allows air to be bled from the tank to the compressor. Delivery rate of the fuel oil metering pump is controlled by the modulating motor through adjustable linkage. Gas System

Fig. 3-11 Fuel Oil metering System (Used with Separate Compressor) Operation Fuel is delivered to the positive displacement metering pump at 10 to 15 psi. Metered oil is delivered to the common port of a 3-way solenoid valve for transfer to the burner nozzle through the normally open port. During pre and post purge, metered oil is delivered to the nozzle. Heavy oil burners have a supplementary nozzle line heater between the metering pump and the 3-way valve.

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SECTION 4 Boiler/Burner Operation

Starting Boiler
Stop! Make sure you have read any followed information for safe and correct boiler operation. If need Permitting before start up, please consult local government. Ensure boiler location meet the requirement of boiler installation with reference to local rules. Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down. Fig 4-3 Open steam gauge isolation valve Preparation a. Make sure that all the followed valves are closed: Boiler main blow down valve, water gauge blow off valve. Fig 4-2 Shut interlock fuel valve for dual fuel burner

Fig 4-4 Open all the valve s on feed water line

Fig 4-1 Close main blowdown valve b. Make sure all the followed valves are opened: Main steam valve/hot water valve/return water valve, steam/hot water gauge isolation valve, all of the valves on water feed line, water gauge isolation valve, all of the valves on oil supply and return oil line, gas supply valve.

Fig 4-5 Open Water assembly isolation valve c. Ensure burner switch to off

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Start Burner Fig 4-6 Burner switch to OFF d. Switch the pump manual/off/auto to off position. a. Ensure all of the fuel valves have been opened. b. Ensure no lockout on programmer safeguard and trouble removed. c. Ensure rotation of burner and oil pump. d. Turn on boiler control selector, and boiler is started. The switch is in manual position while boiler starts from cold, and should be in low fire; after steam is discharged from the safety valve that at the top of boiler, close it. The boiler high/low fire switch is at auto position after pressure is raised. Fig 4-7 Pump switch to OFF e. Turn on the power switch in control panel. Note The operator should check and pay attention to the following while boiler is in operation: a. Water level in water gauge should be slightly waved around the normal, not but wave seriously or water level slur. b. Steam pressure and gas pressure is steadied at normal. c. The sound of blower and water pump rotation should be steady without too loud voice etc. abnormal. d. Slowly open valves esp. high pressure in boiler. f. It is normal that the burner automatically operate at low fire, high fire, shut down or restart etc to follow the change of steam pressure or hot water temperature by responding the signal from pressure/temperature regulator. g. Shut down while suddenly flame out , extra pressure/temperature, and abnormal water level etc. during operation; and check for boiler pressure, water level, fuel supply and gas pressure, air pressure etc.. The professional personnel will undertake troubleshooting if do not operate without any abnormal. h. Air is vented in the boiler room esp. take care fuel leakage. j. Heating temperature and circulating pressure for heavy oil line.

Fig 4-8 Open power switch in control panel f. Switch the pump manual/off/auto to auto position to start pump until boiler water reaches pump off position. For hot water boiler, please switch on feed pump power till boiler and system filled with water, then close boiler exhaust valve and maintain normal pressure at circulating pump and boiler net output. g. Switch light oil/heavy oil to heavy oil position for boiler with heavy oil to start heating system for applicable temperature. h. Turn on circulating pump of oil boiler, with circulating pressure at preset. j. Gas pressure should be at preset for gas boiler.
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Boiler Pressure Control a. The pressure of working pressure controller is set as used steam pressure. For example, the used steam pressure is 8bar, then working pressure controller set is 8bar and the limit pressure set is 9bar. Two knobs located on the top of ratio adjust pressure controller (big and little, see fig.) The big one is used for working pressure set, clockwise rotation increase the pressure and counterwise will decrease. b. The little knob is used to adjust pressure difference between start and shut down. Clockwise rotation will increase the pressure difference and counterwise decrease. For example, the difference set is 0.5bar, limit pressure controller and working pressure sets are 9bar, 8bar, and the boiler operation will change with steam pressure. While steam pressure reaches 8bar, boiler shut down, and while pressure is reduced to 7.5bar, boiler will start automatically. The limit pressure controller is the protection of working pressure controller. While working pressure controller is in trouble or damaged, it performs the second protection to shut down burner and alarm.

Shut Down Boiler

Short term Turn boiler on/off in burner or boiler control panel to OFF. The burner will stop firing, post-purge and then stop. Medium Term (Days) a. Turn boiler on/off in burner or boiler control panel to OFF. The burner will stop firing, post-purge and then stop. b. Shut main steam valve. c. Shut the water feed valve. d. Shut fuel valve. e. Turn the power switch on the boiler control panel to off. f. Shut heavy oil heat source, stop circulating pump. It is recommended to purge the heavy oil pipeline with light oil in case of shut down boiler more than one week to avoid block the pipeline next time. Long Term (Weeks) To store the boiler in a corrosionfree situation there are three practical solutions as follows: a. Wet storage is usually used for shot term shut down, or situations that dry storage can not be carried, and ensure ambient environment not too low. It is recommended blow down first to fully clean PV inside, and fill the boiler with treated water (Maintain PH etc. value). If the water were not oxygen removed, operate boiler for a while, or use some chemical medicine, such as sodium sulfite aqua (properly added this medicine as well during normal operation) to reduce the corrosion in boiler to the least. Water pressure in boiler should be greater than atmospheric pressure; use nitrogen for pressure increase. Deposited carbon on insulations should be cleaned. b. Dry way is usually used for boiler with long term shut down, or environment temperature reduced to zero during shut down. Boiler must be dry completely for dry way to avoid corrosion from humidity. PV Inside and outside surface should be cleaned at all, remove all of the deposit and put enough dry medicine (at least 2 pounds per 3 cubic feet). Heating surface that contact with high
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Fig 4-9 Percent Modulator

Fig 4-10 W.P modulator/Limit pressure Modulator

temperature flue gas may be covered by corrosion-free, grease etc. materials. Remove deposited carbon on insulations and close handholes, manhole, water feed and steam valves. (Note: All should be taken out while start up.) Note 1. For one FBC firetube steam boiler, furnace, firetube and shell are welded to front and rear tubesheet to construct a PV unit. Each part of boiler operates at different temperature, and the rate to working temperature varies due to different water and steam temperature in the boiler. 2. As boiler start from cold, the different expansion proportion will transfer the mechanical pressure to the weld, proper design for boiler ensures that all the pressures can be absorbed. If frequently start from cold, the life of boiler and interval between two inspections would be shorten. It is recommended to possibly slowly heating to start up the boiler and maintain pressure as possible as you can. 3. The best operation: while start from cold, gradually raise the temperature and pressure. The detail is: first heat a few minutes in low fire, then let heat freely spread in the boiler (continue 20-30 minutes); and then blow down boiler suitably to lower top water for heating bottom water. At next circulation, increase heat time and decrease spread time. 4. During actual operation, may be the above is not realism. However, if the boiler had been operated yesterday, the heat collected in the boiler will maintain the temperature at a certain level, so directly start the boiler at that time and reach working temperature/pressure. 5. At the last operation period, shut the steam valve to maintain certain pressure which ensure temperature in boiler do not change greatly during night.

Check one time every 5 years for 24 hours continuous operated boilers with the weld of shell to front and rear tubesheet, and the longitudinal seams is one time every 10 years. Warning: Do not operate safety valve without any proper protection because of high temperature in the valve and its accessory. While manually check it, the open pressure must more than 70% of the rated and pull handle more than 5 seconds.

Burner Operation
1. Boiler Check the boiler water level. Be sure all boiler valves are installed correctly and positioned properly. Set the high limit control slightly above the desired temperature. Set modulating controls at the desired temperature or pressure. 2. Burner Check the electrical power supply to the burner in accordance with the nameplate voltage on all motors and the control circuit. Check the direction or rotation of the motors. Open the housing to check the electrode setting. Check the gas pilot pressure at the pilot regulator. Normal setting: 3 to 6 W.C.(D series ); 18-20 W.C. (S series). Check control linkage for proper movement of the air volume damper and fuel metering components. This can be done by loosening the linkage at the actuator level and manipulating by hand. Check the shutter and adjust low fire setting. 3. Firing Preparations for Oil Burners Prior to initial firing, oil flow pressure and temperature should be verified. Inspect the compressor lube oil sump level. Add oil to bring the oil level to the midpoint or slightly higher in the reservoir sight glass. Make certain that the drive belts or couplings are aligned and properly adjusted. To verify air flow and pressure, momentarily flip the switch ON and immediately turn OFF. The programmer will continue through its cycle, however, without ignition or energizing the fuel
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Joint Inspection
The time interval between two inspections of weld joint is determined by the start times (start from cold to W.P. is one time) after last check.

valves. Observe the air pressure gauge. With compressor running and no oil flow, the pressure should be approximately 10psi. If the burner is a dual fuel model, make certain that the main gas shut off cock is closed and the fuel selector switch set to OIL. Oil Flow D Series Light oil: open all valves in the oil suction and return line. The burner oil metering units are not capable of creating suction. Fuel oil must be supplied to the metering unit at a nominal 10 to 15psi pressure by a circulating supply pump. Heavy oil: Refer to piping diagrams for burners using heavy oil. Note the by-pass valve between the supplies and return lines. At initial system start-up or after prolonged shutdown, start the system as follows: a. A vacuum (or compound pressure-vacuum) gauge should be installed in the oil suction line, and its reading noted. This gauge indicates the tightness of the suction system. b. Open valve No. 1 in the bypass line and close valve No.2 in the supply line to the metering pump. c. Turn on the pre-heater and the circulating pump. Oil will circulate from the tank through the circulating pump and pre-heater, returning to the tank through the bypass and return lines. Observe the oil supply pressure gauge for indication that oil flows is established. If no pressure shows after a few moments, and the vacuum gauge shows little or no suction, stop the circulating pump and re-prime. Heavy oil in the storage tank (I.E. hot well) must be warm enough to permit flow. d. As the system becomes warm, the pressure required for circulation will gradually drop. When the return is warm, open No.2 valve and throttle the flow trough the back pressure valve to the tank via the return line. The pressure in this loop around the burner becomes warm, gradually close valve No.1 in the bypass line. All supply oil will then flow through the burner loop. The system pressure is regulated by the back
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pressure valve. This should be set between 10-15psi (DL & DM models) or 12-20psi (DE models) at the burner inlet after the temperature stabilizes. Heavy oil flow and burning characteristics are dependent on oil viscosity, which in turn requires temperature regulation. A loop heater in the supply line between the circulating pump and the burner heats the oil. The loop heater should be adjusted to give the designed operating temperature. Where the burning characteristics of fuel are unknown, No.4 No. 5L No.5H No.6 80OF -125OF 115 OF -160oF 145 OF -180oF 180 OF -220oF

e. Oil-Air Tank (Lube Oil) Check the lube oil level in the air-oil tank. Inspect oil level regularly. Loss of oil will damage the compressor. Fill the tank with non detergent SAE30 oil to a level midway up the sight glass. Do not overfill the tank. For normal environment use SAE30 oil. For a 32 degree F. and below environment use SAE10 oil. Change oil every 2000 hours of operation. S series Open all valves in the oil suction and return line. The burner oil metering units are not capable of creating suction. Fuel oil must be supplied to the metering unit at a nominal 50 to 70psi pressure by a circulating supply pump. 4. Firing Preparations for Gas Burners A representative of the gas utility should turn on the gas. Determine by a test gauge upsteam of the burner regulator that sufficient pressure exists at the entrance to the gas train. The gas pressure regulator must be adjusted to the pressure required and the pressure setting recorded. On combination fuel models, set the selector switch to gas. On initial start-up it is recommended that the main gas shut-off cock remain closed until the programmer has cycled through pre-purge and pilot sequences to deter. Check for leaks and determine there is adequate

gas pressure available at the burner for operating at full capacity. Check with the local utility if necessary. Check gas pressure at the pilot and the main burner. Close the manual gas valve. 5. Electrical Interference Test Prior to putting the burner into service, conduct the following test to ascertain that the ignition spark will not cause the flame relay to pull in. a. Gas Fired Close the pilot and the main line manual gas valves. Start the burner and at time of pilot trial with just the electrical ignition system energized, the flame relay should not pull in (i.e. be energized) Upon completion of successful test, proceed with start up procedures. b.Oil Fired Disconnect the electrical power to the burner. Disconnect the electric oil safety shut-off valve. Reconnect electric power to the burner. Close the pilot line manual gas valve, if used. Start burner and at the time of pilot trial, with just the supply. Reconnect oil safety shut-off valve and turn on manual pilot gas valve. Reconnect power supply and proceed with start-up procedures. 6. Gas Pilot Flame Adjustment The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator. Normal setting is 18 to 20(S series); 3 to 6 (D series) W.C. when the pilot is burning. The flame must be sufficient to be proven by the flame detector and ignite the main flame. Although it is possible to visibly adjust the size of the pilot flame, obtain a proper DC volt or microamp reading of the flame signal. The flame safeguard amplifier has a meter jack for this purpose. At initial start-up and during planned maintenance, test the pilot flame signal, pilot turndown, and safety switch lockout. 7. Start-up Sequence Gas Burners
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Close the main and pilot gas cocks. Make sure the ON-OFF switch is in the OFF position and the fuel selector switch on GAS. Actuate the manual reset button of the flame safeguard control to close the safety switch contacts. Set the MANUAL-AUTO switch in the MANUAL position. Set the manual potentiometer in low fire position. Open the gas pilot cock. Set the ON-OFF switch to ON. The burner will start and pre-purge. After pre-purge, the ignition transformer and the gas pilot solenoid are energized. Before proceeding, conduct electrical interference and pilot turndown tests if not previously done. On initial start-up it is recommended that the main gas shutoff cock remain closed until the programmer has cycled through prepurge and pilot sequence. Then determine that main gas valve opens. When this is confirmed, turn the burner switch OFF and let programmer finish its cycle. Check to see that gas valve has closed tightly. If ignition does not occur, turn the burner switch off and allow programmer to recycle for a new ignition trial. Turn burner on and after pilot ignition when the flame relay pulls in, the slow opening, motorized, main gas valve is energized. Slowly open the downstream manual shutoff gas cock. Main flame should ignite at this time. The gas valve and air damper continue advancing until high fire is reached. Do not repeat unsuccessful light off attempts without rechecking burner and pilot adjustment. Vent fuel vapors from the combustion chamber after each unsuccessful butterfly valve and air linkage. When low fire is adjusted, shut down burner. Restart several times to be sure the low fire setting is suitable. Readjust if necessary. Never start the burner with fuel vapor in the furnace. In case of emergency, open main power switches and close all fuel valves. After combustion adjustments are satisfactorily set, allow the heating vessel to slowly reach normal operating pressure or temperature. Turn the potentiometer switch to the high fire position. Check high fire at this point using combustion instrument.

Do not disturb established low fire adjustment. Allow the burner to return to low fire position before adjusting high or intermediate settings. High fire combustion analysis typically is 9 to 10.5 percent CO2. Oil Burners The fuel selector switch should be set to OIL. On initial start-up of a combination burner, it is recommended that oil firing be adjusted before gas firing. Gas low firing rate is set to match oil low fire rate. Be sure the ON-OFF switch is in the OFF position and the fuel selector switch is on OIL. Actuate the manual reset button of the flame safeguard control to close the safety switch contacts. Be sure the MANUAL-AUTO switch is in MANUAL position. Set manual modulating control potentiometer in LO fire position. Open the pilot gas valve. Set the ON-OFF switch to ON, The burner will start and pre-purge. After pre-purge, the ignition transformer and the gas pilot are energized. Before proceeding conduct electrical interference and pilot turndown tests if not previously done. Observe the primary atomizing air pressure gauge on the air/oil tank. The gauge reading should be approximately 10psi during pre-purge. When the pilot flame is proven, the programmer will proceed to the main flame position. Allow the burner to operation in low fire, to warm the boiler before moving to high fire. Typically, for No.2 oil, CO2 is 8 to 11 percent at low fire. Turn the manual potentiometer switch to the high fire position. Check high fire combustion at this point. Do not disturb previously established low fire adjustment. Allow the burner to return to low fire position before adjusting high or intermediate settings. The primary atomizing air pressure will increase. The programming control sequences the operation of all controls and components through the starting, ignition, firing, and shutdown cycle. The burner and control system are in staring condition when:

a. The operating and high limit control (temperature or pressure) are below their cutoff setting. b. All power supply switches are closed. c. Power is present at the control panel. Refer to the manufacturers literature on programming controls and burner wiring diagrams for detailed information. a) Begin staring sequence, with burner switch off, and with all manual valves closed. Switch main power on. (POWER ON ) light. b) When firing oil, open the manual oil valves.

c) When firing on gas, open the main manual gas valve. d) When firing on gas, manually reset the high and low gas pressure switches. e) Place the gas/oil selector switch in position for desired fuel. With all limit and operating controls calling for heat, the burner will follow the Flame Safeguard Sequence below. f) When the burner motor starts, open the gas cock. g) If firing on gas, when the main fuel lamp lights indicating pilot flame proven open the manual leak test valve.

Time (s) 0

External Operation Provided the fuel valve is proven closed the burner motor and flame safeguard timer will start. Air flow must be proven before ignition, or the flame safeguard will lockout. If the interlock circuit opens during a firing period, the burner will shut-off and the flame safeguard will lockout. Firing on gas and providing the air flow and low fire have been proven, the air flow and low wire have been proven, the pilot ignition transformer and ignition lamp are energized and the gas pilot valve opens to ignite the pilot.

60

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70

Firing on oil, providing air flow and pilot has been proven, the main fuel lamp lights. When on gas or oil, the main valve opens to ignite the burner at low fire. The pilot ignition transformer is de-energized, and the main safety shut-off pilot valve closes, scanner proves main flame only. If the low/auto. switch is in the auto position, the following will occur: On gas, the butterfly valve and the burner air louver moves to low fire position. On oil, the metering pump and the burner air louver moves to low fire positions.

1) Condition must be corrected and the respective gas pressure switch manually reset before the burner will fire again on gas. 11. Normal Operation Normal operation must be with the MANUAL-AUTO switch selector at AUTO. In automatic operation, the operating cycle always proceeds sequentially through pre-purge, pilot ignition, main flame ignition, run and post purge. The length of purge and ignition trial varies according to the type of programmer used. During the run cycle, burner input is regulated to the load demand by the modulating pressure or temperature control on the boiler. The burner will continue to modulate until the operating pressure or temperature is reached. Programmer control operation should be tested when the burner is initially placed into service, when a control is replaced, and at scheduled intervals in the maintenance program. 12. Shut Down When the operating limit control setting is reached or the burner switch is turned OFF, the following sequence occurs: The fuel valves de-energized and flame will extinguish. The blower motor continues running during post-purge. At the end of the post-purge, the blower motor is de-energized. The programmer returns to its staring position and stops. Unit is ready to restart. Abnormal shutdown might result from motor overload, flame outage, low water, current or fuel supply interruption, combustion or atomizing air pressure below minimum level, tripped circuit breakers, blown fuses, or other interlock devices. Check for cause and correct before restarting burner. Safety shutdown caused by ignition or flame failure will actuate a red indicator light and energize an audible alarm (if so equipped). If the programmer has a non-recycling interlock circuit, any interruption in this circuit during the pre-purge or firing cycle will cause a safety shutdown. This type
57

80

8. Automatic Shutdown Limit or operating controls open: 100 115 Fuel valves close. Main fuel lamp goes off. Flame safeguard timer starts. Flame safeguard timer and burner motor stop. Burner is ready for start up on the next call for heat.

9. Manual Shutdown a. Turn gas/oil selector switch off. Burner shuts down in Automatic Shutdown as above. b. When burner motor stops, close all manual valves. 10. Safety Shutdown a. If any time during the operating cycle a flame failure occurs, the burner shuts down as in Automatic Shut down, with an additional post-purge, and the flame failure lamp is energized. 1) The lockout switch on the flame safeguard control must be manually reset after a waiting period of two minutes, before the burner will fire again. b. If a low water condition occurs, the burner shuts down as in Automatic Shutdown. c. If a high or low gas pressure condition occurs while firing on gas, the burner shuts down as in Automatic Shutdown.

of shutdown requires manual reset of the programming control and must be corrected before

operation can be resumed.

58

SECTION 5 MAINTENANCE
To ensure the continuing efficiency of the boiler, regularly carry out regular routine maintenance procedure as detailed below: Caution If any fault is found during these procedures, shut down the boiler immediately and consult Fulton. Note It is essential that regular checks are made to ensure scale build-up is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler water feed is effective. The lower handhole doors should be removed after three months and the interior of the boiler thoroughly examined. If the scale or sludge build-up is observed, a water treatment specialist should be consulted. Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are obtained. Thereafter, inspections should be carried out at six monthly intervals. the pump starts after water level drops. 3. Shut the valve if the main blow down is open to ensure pump continuous feed water to normal water level and shut down automatically. The first low water and second low water: 1. Turn the Pump MANUAL/OFF/AUTO switch in control panel to OFF position. 2. Reduce water level in boiler with blow down or vaporizing. 3. Check water in water gauge, the burner shut down while water level is dropped to low water position; and the low water alarm sounds while water keeps drop, with the second indicator lights and burner continues to shut down. 4. If the main blow down valve is opened, shut valve, turn the Pump MANUAL/OFF /AUTO switch to AUTO position to ensure pump start. Then boiler water is restored to normal; the second low water indicator will extinguish and alarm will cancel, and burner returns to operation. Check Pressure switch: 1) Start boiler 2) Shut main steam valve 3) Turn the W.P. switch to the greatest. 4) Adjust the high limit pressure switch to the value 0.5bar lower than safety valve preset. 5) Let steam rise up to actuate high limit pressure control. Check the indication on pressure gauge, it should show 0.5 bar lower than safety valve setting. If the indication is wrong, repeat the above. 6) Open main steam valve to reduce steam pressure. 7) Set the W.P. switch at desired pressure, set firing pressure switch to 0.5-1.0 bar lower than W.P. setting. 8) Shut main steam valve.
59

Regular Check
Caution: if your boiler can not pass the following test, shutdown boiler and consult Fulton. After fired the burner, carry out the following tests: Flame detector test Remove the detector from the burner joint, and shield the window, then the burner programmer should be immediately lockout (gas boiler 2-3s, oil boiler 5s.), which needs manual reset to restart. Clean the scanner before reinstall. Water pump Check 1. Reduce water level in boiler through blow down or vaporizing. 2. Check water level in water gauge, and see if

9) Change the above switch set to raise steam pressure actuating high/low pressure switch to change the burner to low fire condition, then shut down burner by the W.P. switch. Warning: Any change of the burner setting should be completed by professional personnel. High water level probe: (if installed) 1. Check if the water feed valve is fully opened.

causing a premature 2nd low water alarm. This is normal and typical of priming where a boiler tries to maintain an overload condition resulting in unstable water conditions. Hot Water Temperature It is recommended that the hot water temperature should be not less than 77. The steam exhausted with flue gas would condensate and then cause corrosion to chimney and boiler when the temperature of hot water applied by the system less than 77, which is close to the dew point. Condensate can seriously affect the boiler intermittent operation. So, control boiler hot water above 77. Note: It is recommended that the lowest water temperature of the boiler should be above 77, if the temperature lower than 77 is needed in the system, and then decrease the water temperature Quick water exchange Do not feed too much water in short time which cause stress raised in boiler pressure vessel. Note: Circulation pump should interlock with burner, that is, when the circulation pump does not work, the burner accompanied to avoid damage to equipment. Continuous water flow Maintain water flow through boiler by system pipeline at any circumstance. Check for three-tee valve and system control to ensure boiler not to be bypassed. Continuous cycle water flow through boiler would keep system temperature more steady. After the blow down and ignition, boiler operator should check the water flow prior to re-ignition.

2. Turn the Pump Manual/Off/Auto switch to Manual position. 3. Start water pump, the boiler is filled and water level will be raised. 4. While water rises to high water position, high water indicator will light, and the alarm will sound, but burner will still keep working; switch the Pump Manual/Off/Auto switch to AUTO position immediately, then pump will stop. 5. Reduce water level in boiler by way of blow down or vaporizing. 6. Boiler water level is gradually recovered to normal position, and the high water indicator will extinguish and alarm will cancel. Evaporation Test to verify low water relay 1. With the burner running, switch off the boiler feed pump and allow the water level in the boiler drops by evaporation. 2. When the water level reaches low water position, the 1st low water relay will function and the burner will stop. 3. Allow the evaporation process to continue until the 2nd low water alarm sounds and the 2nd low water indicator illuminates. 4. Switch the feed pump to the pump AUTO position. 5. The water level will be restored to normal working level, the low water indicator lamp will extinguish and the alarm will cancel. Note: Because the burner shuts down during this test, it is possible that the steam load will rapidly decrease the pressure in the boiler
60

Daily Maintenance
Ensure turn off power supply and fuel supply after shut down. Ensure boiler house is vented at any time. Always check the air inlet of burner to ensure air is vented

without any block. The regular should be carried out blow down to keep boiler and water gauge pipework clean and free from sludge and scale build-up. Boiler blow down 1. Fully open the main blow down valve for a minimum of 10 seconds after boiler pressure is decreased to 0.34MPa. 2. Shut main blow down valve.

Test boiler low water alarm and normal shut down by way of low water probe test. Test boiler high water alarm by way of high water probe test. Carry out regular routine check for the burner as the recommended code from manufacturer. Test boiler flame control by way of flame scanner test. Turn off burner power, remove UV scanner and shield. Connect the power to see if the burner would be lockout at the ignition process. Shut off power supply, replace the UV scanner. Connect power and replace.

Note As well as removing sludge from a boiler, a second and equally important function is to maintain the water quality within the required limits, with caution to the dissolved solids in water. The amount of blow down, and hence time required, is dependent on the amount of dissolved solids in the raw water supply, the percentage condensate return, water treatment chemicals added and the number of hours a day operation etc.. In order to establish the required blow down rate, consult your water treatment specialist who will recommend a water treatment program in terms of appropriate chemicals and the required blow down rate which takes these factors into account. Water Gauge Blow Down 1. Open water gauge blow down valve while the pressure in boiler is lower than 0.07MPa, and then in turn shut the bottom isolation valve and top isolation valve. 2. After blow down, ensure all the isolation valves are opened and all the blow down valves are closed.

Semi-Annually
Caution The boiler must be completely cold before carrying out any of the following procedures. 1. Ensure that the following valves are shut: The main steam valve The feed water isolation valve Fuel valve (oil/gas) 2. Ensure that the power supply to the boiler is switched off. 3. Empty the boiler. It will be necessary to allow air into the boiler before it will drain via the main blow down valve. 4. Remove the handhole and manhole doors and thoroughly inspect the internal surfaces of the boiler, paying particular attention to the junction of the tubes with the front tube plate and the tubes for signs of pitting. Any deposits should be removed and your water treatment specialist consulted. Ensure there are no accumulated deposits of sludge in the bottom of the boiler. 5. 6. Remove the front smoke door. Remove the rear smoke door.

Weekly
Check for the handholes and man hole for signs of leakage. This is particularly important when the boiler is started from new or when gaskets have been replaced. Corrective action taken as soon as a leak occurs can prevent costly repairs later. Check for signs of leaks on all valves and fittings and take the appropriate action.

7. Brush through the tubes to remove any deposits from the products of combustion. 8. Using a wiring brush, clean the internal surfaces of the furnace and the face of the front
61

tube plate. Pay attention to the tube ligaments. 9. Inspect the tube ends for any signs of splitting or burning. These are symptoms of gas returning in the tube ends as a result of poor combustion. e.g. carbon monoxide carry-over. If the tube ends exhibit these signs, consult Fulton. 10. Clean out the rear smoke box. 11. Inspect the door seal for signs of wear and replace if necessary. The first indication of a worm door seal would be evident by signs of black around the external periphery of the door. 12. Examine the internal surface of the door refractory lining for defects. Small repairs may be carried out by cutting out the defective area and replacing with new fiber. 13. Examine the end of the burner blast tube. Clean off any deposits, paying particular attention to the internal lip where deposits can cause irregular flame patterns. 14. Inspect the rear smoke box door seals for deterioration and replace if necessary. 15. Close the hinged front access door by reversing the opening procedure. 16. Re-connect the gas/oil connections. 17. Drain and flush the feed water tank, clean any fitters and the strainer in the feed line. 18. Drain and flush out the blow down separator. 19. Clean oil line, oil strainer and oil tank (oil boiler). 20. Carry out routine maintenance to the burner as following. Note Remember shut off power before any action is taken on the burner. Burner Impeller There is usually no need to clean because of self made by centrifugal designation. Gas Burner Ignition Assembly Remove the air damper linkage, turn the fixed clip upward (for DL175 below is manual rotated screw),
62

then the housing can be turned to right, pay attention the wiring in burner. The ignition assembly is at the right of the burner. Break the ignition electrode terminal to remove the air tube and carefully take the assembly out from the burner head. Oil Nozzle Assembly Remove the air damper linkage, turn the firmed clip upward (for DL175 below is manual rotated screw), then the housing can be turned to right, pay attention the wiring in burner. The nozzle assembly is in the center of the burner. Remove the air tube and oil supply tube, remove the fixed screw and carefully take the assembly out from the burner head. Airing Flame Stabilizer Use wire brush to clean after open the burner. Ignition Electrode Check and clean, check for crack in pottery and replace for crack. Flame Scanner Use clean cloth and do not contact the glass with finger or others. Pay attention to align the glass face to flame. Oil Strainer Remove rear oil pump plate to get the strainer out and use clean diesel oil or other similar solvent. Reinstall it and recover the plate. Replace at least one time every year for once strainer. The detail frequency is up to the cleanness of oil and installation. If not, always wash or replace the core. Note: Exhaust air in system after completion of above. First wash with detergent for nozzle strainer after the nozzle is separated, then wipe residual dirt with clean cloth, do not use any metallic of wood material. Motor No need for maintenance. If the bearing is wrong, replace. If the coil is bad, replace.

Control Panel In general, no need. Do not open the cover unless special situation. If necessary, ask for professional personnel or tighten the screw. Note: The purpose of regular routine check is to ensure no scale build up in boiler to show the feed water is suitably treated. The lower handhole doors should be removed after one months and the interior of the boiler thoroughly examined. If the scale or sludge build-up is observed, a water treatment specialist should be consulted. Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are obtained. Thereafter, inspections should be carried out at six monthly intervals.

Elastomeric Vulcanizates, which form the basis of TOPOG-E gaskets, undergo degradation from many sources including heat, oxygen, stress, and overdosing from certain types of water treatment. This takes the form of material oxidation, the form of material oxidation, hardening/embrittlement and cracking which may take to minimize the effects of such attacks. Water treatment and oxygen attack can be combined by ensuring that the gasket is aligned correctly so that only the extreme edges of the gasket are exposed. If a new gasket leaks after fitting this is almost certainly due to incorrect sealing or excessive tightening, but such an action will seriously reduce the life of the gasket and cause problems later. Undue stress can be avoided by tightening just sufficiently to stop any leakage when fitting cold and before firing the boiler. Fire the boiler and then gradually warm the boiler up, allowing the increasing steam pressure to take over and complete the seal. This will allow the gasket material to contact naturally and follow the topography of the mating surfaces. The securing nut can then be tightened gently by, say, a quarter of turn to ensure a snug fit and prevent the seal from being broken when the boiler is cold and under negative pressure. Gentle warming of the boiler on initial firing after maintenance will also help to ensure that the rubber curer to shape. If the rubber post-cures, the elastic memory will be destroyed and any initial over-tightening will cause the gasket to become hardened and embrittled, leading to cracks and eventual failure. Fitting Instructions Blow down the boiler completely and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows. 1. Disassemble the crab and cover plate and remove the inspection hole assembly. Remove the old gasket and thoroughly clean the mating faces of the cover plate and boiler ring. 2. Place the new TOPOG-E gasket on the cover plate, ensure the gasket is the correct size and is
63

Annually
Repeat semi-annually maintenance. Pay attention to the percentage of CO2, O2, CO in the exhausted gas. It is recommended that the internal inspection interval is no more than 14 months. Weld inspection interval of 24 hours continuous operated boiler is depended on start times after last inspection (the boiler start from cold to W.P. is one time). The shell with front and rear head weld is 1 time every 5 years; and the longitudinal is 1 time every 10 years. More frequent inspection is needed for boilers always start form cold. The annual inspection is carried out by competent professional personnel with necessary instrument.

Fitting New Gaskets

TOPOG-E gaskets have a finite life after installation and must be replaced annually. It is important that the instructions given in this section are adhered to. The boilers are fitted with TOPOG-E gaskets in all the inspection holes of the boiler. These gaskets work very well and millions have been safely used over the last 30 years, however, it is absolutely essential to observe a few simple rules in order to get the last performance from your installation.

seating flat against the plate. Do not use any grease, lubricant or adhesive. If the new gasket is not seated properly before the plate is tightened, the gasket may be pinched causing a failure when the pressure builds up. 3. Position the cover plate in the boiler ring, ensuring that the plate is correctly centered. An off-center cover plate can concentrate forces on the gasket and cut it in two. The cover plate may also drag on the boiler hole ring and fail to seal as the pressure rises. Set the crab and hand tighten the securing nut sufficiently to provide a snug fit. Tighten the nuts a further quarter of a turn using a spanner. Note Ensure the gasket is aligned correctly so that only the extreme edges are exposed to water treatment or oxygen attack. If the gasket is misaligned, overtightening to seal a leak will not prevent subsequent leakage at a later date.

Fig. 5-2 Illustration shows over compressed gasket 4. Gradually warm up the boiler, allowing steam pressure to make the seal. If the gaskets leaks during pressure build up, tighten the securing nut sufficiently only to stop the leakage. It is important to keep the nuts correctly tightened thereafter, this prevents the vacuum developed by cooling on shutdown from feeding and draining the boiler. Note New gaskets fitted to inspection holes located along the bottom of the boiler are more difficult to install without leaking. Small particles of scale or sand tend to run down on the mating surfaces after cleaning but prior to assembling. This condition is likely to have occurred if excess tightening is required to stop a leak before warming the boiler. In this event, the best course of action is to drain the boiler and repeat the gasket fitting procedure. Failure to do so will severely reduce the life of the gasket. 5. Clean and check water gauge glass. Replace gasket for leakage.

Burner Maintenance
Warning Any cover plates, enclosures, or guards anchored to the burner, or any burner related equipment, must remain in position at all times. Only during maintenance and service shutdown can these cover plates, enclosures, or guards be allowed to be removed. They must be replaced, and securely anchored before testing, adjusting, or running the burner related equipment. It is important that you provide support for the housing when in the operation to prevent damage to the hinges and subsequent components. 1. General A maintenance program avoids unnecessary down time, costly repairs, and promotes safety. It is recommended that a record be maintained of daily, weekly, monthly, and yearly maintenance activities.

Fig. 5-1 Illustration shows correct pressure on gasket

64

Electrical and mechanical devices require systematic and periodic inspection and maintenance. Any automatic features do not relieve the operator from responsibility, but rather free from certain respective chores, providing time for upkeep and maintenance. Unusual noise, improper gauge reading, leak, sign of overheating, etc. can indicate a developing malfunction, requiring corrective action. D Series Impeller and Stator Cone Proper clearance between the impeller and the inlet housing and between the impeller and stator cone is not critical and is set at 1/8 nominal. When installing or removing the impeller, it is mandatory to use an impact wrench. Under No circumstances should you use anything other than an impact wrench. Inserting a bar through the impeller blade and using it as a lever will only damage the blade and also void the 5 year impeller warranty. If the impeller is changed to a different width, the stator cone position may require adjustment. This is provided for by means of slotted mounting holes in the blast tube. Loosen the three screws to reposition the cone. If a wide impeller is used to replace a narrower one, it may be necessary to trim the vanes for additional clearance. Firing Head Inspection Disconnect the damper linkage, release the impeller housing latch and swing the housing open for access to the firing head. Inspect the flame scanner lens to be sure it is clean and the support tube is in proper position to sight the flame through the hole in the diffuser. Inspect the lead wire to the ignition. It must be firmly attached and should be clean and free of cracks. The oil nozzle should be inspected periodically depending on the grade of oil burned and the cleanliness of the environment. Pilot and Ignition Electrode The ignition transformer requires little attention other than making sure the ignition wire is firmly attached to the transformer and the electrode. Be sure the wire insulation is in good condition and not grounded. Failure to keep the ignition electrode clean and properly set can cause faulty operation.
65

No adjustment is required except proper positioning of the electrode wire. Flame Scanner The scanner must be clean. Even a small amount of contamination will reduce the flame signal. Wipe the scanner lens with a clean soft cloth.

Fig.5-3 Infrared Scanner

Fig 5-4 UV Scanner Oil Nozzle Successful burner operation requires use of the proper style nozzle tip and keeping the orifice clean. Standard nozzle tips furnished on the burners are of a special emulsifying type which insures proper mixing with the air steam. Unsatisfactory performance and loss of efficiency can result from the use of nonstandard nozzle tips. If the burner flame becomes stringy or lazy, it is possible that the spring is not properly in place or the nozzle is clogged. This problem is usually indicated by an abnormally high reading on the atomizing air pressure gauge on the air-oil tank. To remove the nozzle, disconnect the oil and air tubes to the nozzle tip and swirler. To clean the nozzle,

unscrew the tip from the nozzle body. Use care not to distort the tube. Hold the nozzle body in a vise or use two wrenches, one on the body and one on the tip. Disassemble the nozzle tip. Carefully clean all parts in solvent and reassemble the nozzle. To insure proper atomizing, the tip must be screwed in tightly with the swirler seating spring pressing the swirler tight against the nozzle tip. Turn the swirler a few times to be sure it fits snugly in the nozzle and the spring is pressing the two parts firmly together. When reinstalling, be sure the nozzle is centered with the proper distance from the diffuser. Caution Do not attempt to use wire or a sharp metal tool to clean the nozzle orifice as this will distort the fine orifice and ruin the nozzle. Use a sharp pointed piece of soft wood. Diffuser The diffuser is factory set and does not require attention under normal operating conditions. If fouled with carbon, the diffuser should be removed for cleaning. First remove the electrode and scanner leads, the gas pilot assembly, air and oil tubes and the diffuser. Mark the diffuser relative position to the blast tube, with a scribed or pencil line where the three mounting screws are located, to insure that the diffuser is placed back in the same position. Remove the three screws holding the diffuser to the blast tube and slowly pull the diffuser along the blast tube towards the firing head. Keep the diffuser as parallel as possible. If it should became stuck or tight, do not apply any tool which would distort the shape or blade configuration. A small wooden block tapped gently against the diffusers outer edge will help expedite its removal. Clean all carbon from the diffuser vanes and reinstall in reverse order of disassembly aligning the diffuser with the scribed marks. Do not attempt to drive the diffuser back along the blast tube with anything other than a small block of wood tapped against the diffusers outer edge. When reinstalling, be sure the diffuser is centered. Firing Rate Controls Check all rods and linkages. Make sure all connections are tight. Adjust if necessary. Readjust the burner if necessary.
66

Note It is essential that the cam spring, cam follower arm at the pivot be greased sparingly every month to ensure smooth operation of the cam assembly. Regular automotive bearing grease should be used. Burner Mounting Inspection The seal between the burner flange and furnace front plate must not permit combustion gases to escape. Periodic inspection is important. Refer to the installation: the area between the outside circumference of the dry oven and existing refractory should be packed with Kaiser refractory MonoT-9 Airset or equal within two hours after coating the dry oven with Trowleze. Fuel Oil System Fuel Oil Circulating Pump Failure of the circulating pump to deliver sufficient oil may be due to one of the following reasons: 1. Insufficient fuel oil in the storage tank. 2. Suction line or check valve clogged. 3. Air leaks or air traps in the suction line. If the line has a high point at which an air trap can occur, the line must be changed. 4. Oil strainer clogged(line strainer or burner strainer) 5. Suction line piping too small. 6. Three phase pump motor operating on single phase of fuse failure. 7. Pump rotating in wrong direction. 8. Low voltage applied to pump motor. D Series Air-oil Metering Pump Both the integral air-oil metering pump for light oil and the heavy oil metering pump are precisely fitted units employing a seal on the shaft to prevent oil leakage. Internal wear can take pace due to dirt in the oil and may in time result in excessive clearances, reducing pump capacity. Once adjusted, the pump will continue to operate with a minimum of readjustment. If burner failure appears to be caused by the metering pump, check the following: 1. See that the oil is at sufficient level in both fuel oil tank and air-oil tank on burner.

2. Make sure all valves between the fuel oil tank are open. 3. Be sure the oil suction line is not air bound and check the suction line strainer. 4. Check the low fire setting of the metering pump to be sure it has not been disturbed. 5. Make sure the pump turns freely. 6. Inspect the burner oil nozzle for clogging. Whenever an oil metering pump fails to deliver full capacity or pressure , order a replacement pump at once and return the old pump for repair or exchange(where allowed). Primary Air Compressor The air compressor itself requires little maintenance, however its life is dependent upon sufficient clean, cool lubricating oil. The oil level in the air-oil tank must be checked regularly. Lack of oil will damage the compressor. Disassembly or field repairs to the air compressor are not recommended. Check the air-oil tank sight glass for proper oil level. The level should be kept at midpoint up the glass. The compressor rotor must turn freely. All tube connections must be air tight. Alignment of the compressor and motor sheaves and proper belt tension are important. Belt tension is adjusted according to the displacement on the belt with thumb pressure. The displacement should be 3/8 to 1/2 inch. To adjust, loosen the two bolts on the compressor mounting flange and the three setscrews which hold the compressor in place.The mounting flange is slotted at the top, which permits belt tightening. If the slot in the mounting flange is insufficient for obtaining proper belt tension, the modular base has two extra holes for this purpose. Move the top bolt to the next hole and adjust. Tighten bolts and setscrews. Replace belt guards. If belt becomes frayed or cracked, replace it. Caution Do not attempt field repair the compressor. Installation of a new compressor is mandatory. Send the old compressor in for repair or exchange (where allowed) Air Cleaner
67

Never operate the compressor without the air cleaner in place. The cleaner should be cleaned at regular intervals. The correct oil level must be maintained in the air cleaner. Use the same oil used for air compressor lubrication. Oil-Air Tank Check the lube oil level in the oil-air tank. Inspect oil level regularly as loss of oil will damage the compressor. Change oil every 2000 hours of operation. The oil-air tank should be drained once a year and thoroughly flushed. Remove the mist eliminator pads from the upper section of the tank, wash thoroughly in kerosene and dry. Refill with non detergent SAE 30 oil to a level midway up the sight glass. For normal environment use SAE30oil. For a 32 degree F. and below environment use SAE10 oil. Oil Level Sight Gauge The oil level sight gauge can be cleaned by removing it from the air-oil tank and soaking it in a detergent solution. If cleaning the gauge proves unsatisfactory, replace it. Compressor Inlet Oil Strainer (Lube oil Strainer) The lube oil strainer prevents foreign materials from entering the compressor. The strainer screen must be cleaned at regular intervals. The screen is easily removed for cleaning by unscrewing the bottom plug. Immerse in solvent and thoroughly clean. D Series Nozzle Line Heater Nozzle line heaters damaged by water accumulation, do not qualify for warranty or exchange service. Failure to prevent water accumulation inside the heater manifold constitutes improper care. Completely drain the heater manifold periodically. This should be part of the preventive maintenance program. Maintenance consists primarily of removing the heating element from the manifold and scraping any accumulation of carbonized oil or sludge deposits from the heat exchange surfaces. Before breaking electrical connections to the heating elements, mark all wires and terminals to

assure correct replacement of wires. Periodic cleaning is necessary to prevent over heating or burn out of the elements. If operation of the heater becomes sluggish, examine the elements and clean as required. Inspect the manifold each time the heater is removed. Flush all accumulated sludge and sediment before reinstalling the heater. Heater must be full of oil before power is turned on. Oil Strainer Oil strainers should be cleaned frequently to maintain a free and full flow of fuel. The strainer screen must be removed and cleaned at regular intervals. The screen should be removed and cleaned thoroughly by immersing it in solvent and blowing it dry with compressed air. Light oil strainers should be cleaned each month. Heavy oil strainers should be checked and cleaned as often as the experience indicates the necessity. Gas System The burner output will increase with the reduction of pressure in combustion room if the gas actuator is damaged for mechanical or electrical accident.

Because of the many types of flame safeguard systems applicable to this equipment, complete descriptions of electrical systems are beyond the scope of this manual. An individual electrical schematic drawing is shipped with each burner and complete operation and troubleshooting instructions are available from the various flame safeguard system manufacturers. Electric Motors Motor supply voltage must not more than 10 percent from nameplate ratings. At initial start-up and at least once a year thereafter, check the motor current with a meter while the burner is in high fire position. If the reading exceeds the nameplate rating plus service factor, determine the cause and correct it immediately. In dusty locations, clean the motor regularly to assure adequate cooling. Lubricate in accordance with the manufacturers instructions. Extended Shutdown When shutting down the burner for an extended period of time, the operator should use the following general guidelines to protect the burner from its surrounding elements. This will increase the operating life of the burner. 1. Turn the main electrical disconnect switch to the burner to OFF. 2. Close all main fuel valves. 3. If the burner operates in a damp environment, cover it with plastic to protect all electrical components from moisture. Remove the flame safeguard control and store in a dry atmosphere.

Fig 5-5 Gas Actuator Electric System

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Common Gas Line

Low Gas Pressure Switch Adjustment Procedure For SKPNGgas trains with the low pressure regulator 1) Set the pressure regulator to a value, which produces the desired burner pressure at high fire. 2) Determine the pressure drop of the selected gas valve by use of flow chart. (If two safety valves are installed determine the pressure drop of both valves.) 3) Add the value of the regulator setting and the pressure drop across the valves. 4) Divide this sum by two. This is the setting for the low pressure switch.

69

Maintenance Flow Chart

Periodic Testing Recommended Check List Item Gauges, monitors, and indicators Instrument and equipment settings Firing rate control Frequency Daily Service by Operator Remarks Make visual inspection and record readings in log Make visual against recommended specifications Verify factory settings Verify factory settings Check with combustion teat Make visual inspection

Daily

Operator

Weekly Semi-annually annually

Operator Service Technician Service Technician Operator

Flue, vent, stack, or outlet dampers Igniter

Monthly

Weekly

Operator

Make visual inspection, check flame signal strength

Fuel valves Main Weekly Operator Open limit switch, make sure valve close Perform leakage test rrefer to instructions

Pilot and main gas or main oil

Annually

Service technician

Combustion safety controls Flame failure Weekly Operator Close fuel supply, chek safety shutdown Check flame signal reading on control display or test with meter-low and high fire. Required after any adjustment to flame, scanner mount or pilot adjustment. See pilot turndown test instructions

Flame signal strength

Weekly

Operator

Pilot turndown tests

As required/Annually

Service technician

Refractory hold in

As

Service technician
70

Maintenance Flow Chart

Periodic Testing Recommended Check List Item Frequency required/Annually Low water fuel cutoff and alarm Daily/weekly Semi annually Annually Operator Operator Service technician Refer to boiler instructions-Slow drain test as per ASME pressure vessel code Refer to boiler instructions Service by Remarks

High limit safety control Operating control Low housing, and damper position interlocks Atomizing air steam interlock High and low gas pressure interlocks High and low oil pressure interlocks High and low oil temperature interlocks Fuel valve interlock switch Combustion air purge switch Burner position interlock Low fire start interlock

Annually Monthly

Service technician Operator

Refer to boiler instructions Refer to boiler instructions

Annually

Service technician

Refer to boiler instructions

Monthly

Operator

Refer to boiler instructions

Monthly

Operator

Refer to boiler instructions

Monthly

Operator

Refer to boiler instructions

Annually

Service technician

Refer to boiler instructions

Annually

Service technician

Refer to boiler instructions

Annually

Service technician

Refer to boiler instructions

Annually

Service technician

Refer to boiler instructions

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Maintenance Flow Chart

Periodic Testing Recommended Check List Item Automatic changeover control(dual fuel) Safety valves Frequency At least annually Service by Service technician Remarks Refer to boiler instructions

As required

Operator

In accordance to ASME pressure vessel code Refer to boiler instructions

Inspect burner component

Semi-annually

Service technician

72

SECTION 6 TROUBLE SHOOTING

Problem Gas burner will not start

Cause Power supply

Remedy Check air flow switch in control panel Check fuses in control panel

Scale or sludge build up on low water probe Loose wire connection Gas supply Gas pressure switch Steam pressure switch Boiler water not at normal Main fuel valve not full closed(for FBC 400) Oil burner will not start Power supply Scale or sludge build up on low water probe Loose wire connection Gas supply Gas pressure switch Steam pressure switch Temperature control switch (for hot water boiler and heavy oil boiler) Boiler water not at normal

Check low water probe for scale Reset low water controller Check connections to all components Check gas pressure Ch k i ki Check gas pressure R t it h Check steam pressure switch Ch k bl d th l Check boiler water indication Check main fuel valve l d it h

and position switch

Check air flow switch in control panel Check low water probe for scale Reset low water controller Check connection s to all components Check gas pressure Ch k i ki Check gas pressure R t it h Check steam pressure switch Ch k bl d th l l d Reset temperature protection button it h

Check boiler water indication

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Problem

Cause Main fuel valve not fully closed(for FBC 400)

Remedy Check main fuel valve and position switch

Blower auto stop after gas burner start 5 seconds

Air pressure switch not act

protection

Check air pressure protection switch (In normal condition, the switch contact should close while blower pre purge.) Check gas pressure switch Reset gas high/low pressure protection Check temperature switch Reset temperature protection switch Check oil pressure switch Reset oil pressure protection button (in normal condition, the oil pressure switch contact close.) Check compressor and air protection switch (In normal condition, the pressure protection contact should be closed) Adjust damper feedback block( the block is at the center rod of damper)

Gas pressure switch not close Temperature control switch action(for heavy oil heater) Oil pressure close switch not

Not enough air pressure from compressor

The blower purge at big damper but not do the next The blower purge at little damper but not do the next Boiler will not ignite

The big damper feedback contact does not act

The little damper feedback contact does not act

Adjust damper feedback block and related cam(the cam is in serve motor)

Ignition electrode dirt or crack Dirty or damaged scanner

Clean ignition electrode and check crack

Use clean cotton and check signal voltage (in normal condition, it is 5v) Adjust distance( in normal condition, the distance between electrode and steel rod is 3-5mm) Open manual, replace gas bottle.

Incorrect distance of ignition electrode

Manual valve in ignition line is not open or the fuel exhausted

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Problem

Cause Ignition transformer burn out

Remedy Meter transformer resistance ( in normal condition, the primary resistance is about 20 and the second is about 1000. Consult professional adjustment personnel for

Ignition damper too big

No reason shut during operation

down

Normal

The set steam pressure is reached, boiler will auto start while pressure is less than setting. Clean with cotton cloth and check signal voltage(in normal condition, signal voltage is 5V) Check fuel supply Check gas pressure, notify Gas company

Scanner trouble

Fuel shut during operation Not enough gas pressure (gas boiler) Boiler will not maintain pressure Gas supply Oil supply Steam pressure switch

See above See above Check steam pressure switch, readjust or replace Check water treatment advisor Check steam traps and replace as necessary Clean flue side of boiler Reduce treatment Dump return tank, flush system or stop treatment for a week. Drop boiler water(in normal condition, boiler water should be in middle of the glass sight. Check for tightness and clean

Scale build up in boiler Steam traps Dirty flue Steam overload Wet stream Too much chemical

Too high water level

Pump will not cut off

Earth connection

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Problem

Cause Probe connection Dirty probes Water level relay damaged

Remedy Check for tightness and clean Clean or replace Replace Check For Bad Steam Traps Ch k f h k l i t f Check and clean if necessary Replace pump Check for tightness and clean Clean or replace Replace Check for tightness and clean Check for tightness and clean Clean or replace Replace Check for tightness and clean d li

Feed pump runs but does not put water into boiler

Air/steam lock in pump Blocked water feed line Impellers damaged

Feed pump will not start in time

Probe connections Dirty probes Water level relay damaged Earth connection

Low water alarm /burner shut off will not act in time

Probe connections Dirty probes Water level relay damaged Earth connection

Other troubles: The boiler program control is Honeywell 7800 with automatic self check. If user chose the display, it will bring about convenience and provide information for the service personnel, the following table is the program trouble information: Honeywell 7800 trouble information Fault Number Fault 1 Fault 2 Annunciation Message *No Purge Card* *AC Frequency/Noise* Description Purge card problem. Lockout due to inability to take minimum number of samples.

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Fault Number Fault 3 Fault 4 Fault 5 Fault 6 Fault 7 Fault 8 Fault 9 Fault 10 Fault 13 Fault 14 Fault 15 Fault 17 Fault 18 Fault 19 Fault 20 Fault 23 Fault 24 Fault 25 Fault 28 Fault 31 Fault 32 Fault 33 Fault 35

Annunciation Message *AC Line Dropout* *AC Frequency* *Low Line Voltage* *Purge Card Error* *Flame Amplifier* *Flame Amp/shutr* *Flame Detected* *Preignition ILK* *Airflow Sw. On* *High Fire Sw* *Flame Detected* *Main Flame Fail* *Flame Detected* *Main Flame Ign.* *Low Fire Sw. Off* *Airflow Switch* *Internal Fault* *Internal Fault* *Pilot Flame Fail* *Low Fire Sw. Off* *Airflow Switch* *Preignition ILK* *Internal Fault*

Description Lockout due to AC line dropout detected Lockout due to AC line frequency too fast. Lockout due to insufficient AC line voltage. Purge card parity is bad. Flame sensed when checked for ampli-check system. Flame sensed when checked for shutter-check system. Flame detected during Standby and time limit has expired.) Preignition interlock open during Standby and time limit has expired. Airflow switch shorted and limit has expired in Standby(demand was present) High Fire switch open and time limit has expired during prepurge. Flame sensed when shutter open and no flame is expected during Standby. Main flame failure during Run after flame has been on for a while. Flame detected during Purge or Waiting, when no flame should exist. Flame loss detected, main flame did not ignite or failed during first 10s of Run Low Fire switch open time limit has expired during Waiting. Combustion airflow interlock fault during Waiting. Flame interlock is enabling fuel valves and no flame is present. Flame interlock feedback indicates it is not enabling main valve. Pilot flame failure. Low fire interlock switch failed to close during Run. Airflow switch failed to make or opened. Preignition interlock opened Safety relay feedback showed off when it should be on.

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Fault Number Fault 36 Fault 37 Fault 38 Fault 39 Fault 40 Fault 41 Fault 42 Fault 43 Fault 44 Fault 45 Fault 46 Fault 47 Fault 50 Fault 51 Fault 52

Annunciation Message *Internal Fault* *Internal Fault* *Internal Fault* *Internal Fault* *Internal Fault* *Main Valve On* *Pilot Valve 1 On* *Ignition On* *Pilot Valve 2 On* *Low Fire Sw. Off* *Flame Amp Type* *Jumpers Changed* *Jumpers Wrong* *Flame Too Strong* *Internal Fault*

Description Main valve relay feedback showed off when it should be on. Pilot valve relay feedback showed off when it should be on. Ignition relay feedback showed off when it should be on. Pilot valve 2 relay showed off when it should be on. Safety relay feedback on when it should be off. Main valve relay feedback showed on when it should be off. Pilot valve relay feedback showed on when it should be off. Ignition relay feedback showed on when it should be off. Pilot valve 2 relay feedback showed on when it should be off. Low fire switch opened. Type and/or FFRT changed since initial read. Field jumpers have changed since initial read. Illegal jumper combination selected (as defined by the burner sequence). Measured flame signal is to strong. Pilot valve 2 relay feedback showed off when it should be on.

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SECTION 7 WARRANTY
3 Year Conditional Warranty On the Fulton Boiler Pressure Vessel
Fulton China LLC will repair or replace F.B factory any Fulton pressure vessel, which, within 3 years of the date of sale from factory, is found of be defective in workmanship or material, provided this equipment is installed, operated and maintained by the buyer in accordance with the Fulton instruction manual and approved practices, and that the water quality used in the system has been regularly checked to meet the standards for ideal and proper boiler feed water during the warranty period. This warranty does not cover damage or failure that can be attributed to corrosion, (including oxygen pitting) scale or dirt accumulations, or lack of water conditions. The warranty does not include labor charges of any kind. In the event a failure reported. Fulton will require an analysis of the boiler feed water to determine that acceptable water conditions are present at the installation site as well as documentation on the feed water treatment employed since the installation of the boiler. Consult Fulton China LLC Feed water treatment and proper daily blow down procedures are very important in keeping your boiler heating surface free of scale formation, pitting, oxygen corrosion and foaming or bouncing water. Suitable feed water treatment will prolong the boiler life. A thorough boiler inspection should take place during the first three months of operation to access the effectiveness of boiler water treatment techniques, including analysis of potential oxygen pitting. It is the owners responsibility to assure safe operation of the boiler. To avoid corrosion, scale or dirt accumulations, it is recommended that a daily blow down procedure be instituted. The boiler power should be left on during daily blow down so that correct operation in the low water relay may be checked. While blow down, the boiler pressure will drop significantly. While blowing boiler down with power on, it is normal to hear the boiler feed pump come on. The burner should no turn on. If the burner does come on, turn the boiler off and contact our factory immediately. Corrosive acid and chlorine based chemicals in the atmosphere can be damaging to this boiler. It is the owners responsibility to have the boiler room periodically tested to assure these damaging chemicals are not present.

1 Year Standard Warranty

A Fulton China LLC will warranty other part which within 1 year of the date of sale from factory is found to be defective in workshop or material, provided the equipment has been installed, operated and maintained by the buyer in accordance with the operating instruction manual provided with the equipment and generally accepted approved practices, and on the provision that the buyer gives proper notification in writing as soon as the defect becomes apparent, and that he has properly filled out and returned his warranty card. Fulton will in charge of repair or replace the original equipment without any pay. This warranty does not include labor charges of any kind.

B Fulton China LLC does not provide any warranty for parts manufactured by others.
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C The working voltage of electrical controls in Fulton boiler should be 110V +/-10%. If the user does not ensure the constant voltage, install constant voltage power. Otherwise the electrical element damage caused by not required voltage will not within the warranty.

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File Card for Fulton Boiler User

Boiler Model : ( ( Boiler Series No. User: Address: Contact With: Purchase Date: Address & Tel.: Direct Maintenance Personnel Indicate if your boiler has installed the following: Oil/Gas Strainer
( ) YES ( ) NO (

)Steam )Oil

( (

) Hot Water ) Gas ( )Dual ( ) Electric

Boiler Power:

Tel.: Sales Agent name

Water Treatment Equipment

) YES ( ) NO

Voltage Constant
) YES ( ) NO

110V +/-10% or 220V +/-10% (

Installation Date: Boiler is used for: This boiler is (

Installation Place:

) Replace the original one (

) New one

Please read carefully the manual provided by Fulton and operate and maintenance your Fulton boiler as the manual. Note: 1. Maintain the control panel input power at the range of 380 V/50 HZ/3 P or 480 V/60HZ/3P Otherwise the controls would be burn out. It is recommended to use constant voltage regulator. If the blower and control panel of your boiler both use with 110 /1 or 220V/1 phase, fit with 110 or 220V high accuracy constant voltage regulator of 3kw. 2. We do not guarantee to repair the problem that caused by boiler feed water not agree with the manual (such as not install soft water equipment). 3. Please install fuel pipeline strainer, otherwise the accident caused by this would be undertaken by user. 4. We reserve the right to change specifications and size for continuous improvement without notice.

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Warranty Card for Fulton Boiler User

Boiler Model: ( ( Boiler Series No. User: Address: Contact With: Purchase Date: Address & Tel.: Direct Maintenance personnel Please indicate if your boiler has equipped with the following accessories: Oil/Gas Strainer
( ) YES ( ) NO (

) Steam ) Oil

( (

) Hot Water ) Gas ( ) Dual ( ) Electric

Boiler Power:

Tel.: Sales Agent name

Water Treatment Equipment

) YES ( ) NO

Voltage Constant
) YES ( ) NO

110V +/-10% or 220V +/-10% (

Installation Date: Boiler is used for: This boiler is (

Installation Place:

) Replace the original one (

) New one

Thanks for buying Fulton boiler, please complete the following questions and return to us: Is the first time you buy Fulton boiler? If replace the original boiler by this one?
( ( ) YES ( ) YES ( ) NO ) NO

If YES, please indicate the replaced ones name and manufacturer: If the original one is Fulton Boiler, the Model is: If the original one is Fulton Boiler, Please state the reason: If the original one is not Fulton, Please state the reason:

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Warranty Card for Fulton Boiler User

How do you know about Fulton? Which impressed you most among the features of Fulton boiler? ( ( ) Easy to operate ) Efficiency ( ( ) Easy to maintain ) Safety ( ) Constancy

or others

Will you purchase Fulton Boiler again?

( ) YES ( ) NO

Please state the reason:

Please read carefully the manual provided by Fulton and operate and maintenance your Fulton boiler as the manual. Note: 1. Maintain the control panel power at the range of 380v/50hz/3 phase or 480v/60hz/3 phase. Otherwise the controls would be burned out. It is recommended to use constant voltage regulator. If the blower and control panel of your boiler both use with 110 V/1 or 220V/1 phase, fit with 110 V or 220V high accuracy constant voltage regulator of 3kw. If blower with 380v/3 phase or 480v/3 phase while controls with 110 V/1 or 220V/1 phase, then fit with 110 V or 220V high accuracy constant voltage regulator of 1kw. 2. We do not guarantee to repair the problem that caused by boiler feed water not agree with the manual (such as not install water softener equipment). 3. Please install fuel pipeline strainer, otherwise poor combustion, wear in oil pump, risen percent of troubles and electric solenoid valve leak etc. accident will take place. This card is valid until having been filled out and return to HANGZHOU Fulton Thermal Equipment Co., Ltd (may be copy) within 40 days after purchase. Hangzhou Fulton Thermal Equipment Co., Ltd. No. 9 18th streets Hangzhou Economy & Technology Development Area, Hangzhou 310018 P R China

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