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Fulton Vertical Coil Design Thermal Fluid Heaters

1. 2 40 000805 Y2 NPT spring loaded thermocouple 2 FT Stock 2 40 000830 Thermocouple wire 1 1 ft Stock 2 40 000798 Thermocouple splice kit 1 05 Stock 2 40 000799 Thermocouple splice kit 05 Stock 2 40 001000 6 probe 150 170 F Adj Thermometer Stock Deaerator Tank Parts 2 30 000551 Liquid level HG34 4 3 1 95 Stock 2 30 000552 NEMA 4 Liquid level HW34 10 32 4 69 Stock 2 30 000553 Explosion proof HR34 10 36 4 71 Stock 2 40 000730 Liquid level switch L4 high amp explosion proof 4 22 1 92 Stock 2 30 000554 Magnetrol level switch 4 30 000200 2 way nitrogen kit SV not included 2 weeks 2 30 000138 Fairchild N2 reg 66162 2 150 2 94 1 34 Stock 2 30 000869 3 4 gate valve fill 2 30 000214 3 4 15 series 19 V stamped brass safety valve 2 9 Stock 2 30 000215 1 15 series 19 V stamped brass safety valve 4 3 1 95 Stock 2 30 000216 1 1 4 15 series 19 V stamped brass safety valve 6 75 3 1 Stock 2 30 000016 1 1 2 15 series 19 V stamped brass safety valve 12 4 5 63 Stock 2 30 000217 2 15 series 19 V stamped brass safety valve 14 85 6 75 Stock Electric Heater Parts N Model 2 40 000910 Main grame for Athena sequencer 2 2 1 0 Stock 2 40 000911 Step card white A 05 Stock 2 40 000912 Step delay yellow A 05 Stock 2 40 000913 Signal card green A 05 Stock 2 40 000914 Starter card black A 05 Stock 2 40 000105 Honeywell 5 step sequencer 10 2 4 64 Stock 2 40 000107
2. 2 40 000648 3BR1015 2PBO Overload 1 5 6 amp 45 2 Stock 2 40 000566 3BR1015 2NBO0 Overload 4 1 6 amp A5 2 Stock 2 40 000573 3BR1015 2SBO Overload 3 12 amp 45 2 Stock 2 40 000651 3BR1025 2QB0 Overload 6 25 amp 45 2 Stock 2 40 000716 3BR1035 2UB0 Overload 13 50 amp 45 2 Stock 2 40 000656 3BR1045 2EB0 Overload 23 75 amp 45 2 Stock 2 40 000822 3BR1045 2EB0 Overload 25 100 amp Stock Panel Box Air Conditioner amp Parts 2 40 000997 Panel Box Air Conditioner 49 6 22 6 1 week 2 45 000468 5 Minute Time Delay Relay for A C 5 3 Stock 2 45 000469 Relay Base for 2 45 000468 2 1 Stock Stepdown Transformer 2 40 000441 75KVA Stepdown Transformer 480 120 50 60hz 12 5 46 1 week 2 40 000443 1 5KVA Stepdown Transformer 480 120 12 5 46 1 week 2 40 000445 1KVA Stepdown Transformer 480 120 50 60hz 12 5 46 Stock 2 40 000440 1KVA Stepdown Transformer 208 120 Stock Pressure Gauges amp Accessories 2 30 000529 0 100 PSI Panel Pressure Gauge heater outlet 44 2 Stock 2 30 000530 0 200 PSI Panel Pressure Gauge heater inlet 44 2 Stock 2 30 000531 30 0 60 PSI Panel Pressure Gauge pump suction 38 17 Stock 2 30 000342 0 200 PSI Liquid Filled Gauge 56 25 Stock 2 30 000343 0 400 PSI Liquid Filled Gauge 56 25 Stock 5 21 000274 Single Gauge Panel Stock 5 21 000273 Dual Gauge Panel Stock 5 21 000272 Triple Gauge Panel Stock 2 40 001003 Stack Thermometer 9 Probe 12 NPT PUMPS Allweiler Un mounted Pumps
3. 2 30 001680 NTT 32 160 w Mechanical Seal i 2 30 001041 NTT 32 200 w Mechanical Seal x 2 30 001681 NTT 40 160 w Mechanical Seal 7 2 30 001020 NTT 40 200 w Mechanical Seal a 2 30 001021 NTT 50 160 w Mechanical Seal 2 30 001684 NTT 50 200 w Mechanical Seal 2 30 001022 NTT 50 250 w Mechanical Seal 2 30 001685 NTT 65 160 w Mechanical Seal 2 30 001036 NTT 65 200 w Mechanical Seal 2 30 001035 NTT 65 250 w Mechanical Seal X 2 30 001034 NTT 80 160 w Mechanical Seal i 2 30 001031 NTT 80 200 w Mechanical Seal 2 30 001033 NTT 80 250 w Mechanical Seal 2 30 001032 NTT 100 200 w Mechanical Seal i Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 147 2 30 001040 NTT 100 250 w Mechanical Seal Long Lead Time check with factory for delivery amp impeller trim size Allweiler Full Size Impellers 2 30 001051 NTT 32 160 Impeller 170mm 4 8 2 18 i 2 30 001120 NTT 40 160 Impeller 170 mm 4 98 2 26 i 2 30 001122 NTT 65 160 Impeller 170 mm 4 62 2 1 2 30 001123 NTT 80 160 Impeller 180 mm x 2 30 001126 NTT 40 200 Impeller 205 mm 6 62 3 01 Long Lead Time check with factory for delivery amp impeller trim size ALLWEILER SPARE PARTS LIST Common Parts For NTT 25 200 32 1 60 4200 4250 50 1 60 50 200 32 200 50 250 65 1 60 and 80 160 65 200
4. 4 30 000106 Seal Kit 1 58 72 Stock 4 30 000126 Rebuild Kit Includes seal kit 3 12 1 42 Stock 2 30 001030 400 1 Casing Gasket 206 x 217 5 x 5mm 01 0 Stock 2 30 001043 400 2 Gasket 257 x 269 x 5 01 0 Stock 2 30 001044 400 13 Gasket 72 5 x 88 x 5 mm 01 0 Stock 2 30 001045 321 4 amp 321 3 Ball Bearing 4 18 Stock 2 30 001048 461 1 Set of Packing ra 05 Stock 2 30 001049 433 2 Mechanical Seal 26 12 Stock 2 30 001050 210 1 Shaft 4 46 2 03 Stock 2 30 001055 Complete 360 Bearing Frame 30 52 13 87 Stock 2 60 000153 EP 2 Grease 10 14 4 61 Stock Common Parts For NTT 65 250 80 200 80 250 100 200 100 250 and 125 250 2 30 001029 400 2 Casing Gasket 01 0 Stock 2 30 001205 400 8 Gasket 01 0 Stock 2 30 001203 461 1 Set of Packing 01 0 Stock 2 30 001200 433 2 Mechanical Seal 4 18 Stock 2 30 001038 210 1 Shaft 3 0 1 36 Stock 2 30 001204 321 3 321 4 Ball Bearing 1 42 65 Stock 2 30 001058 Complete 470 Bearing Frame 53 84 24 47 Stock 2 60 000153 EP 2 Grease 10 14 4 61 Stock Dean s Un mounted Pump includes impeller truck ship only call for impeller trim size 2 30 002000 RA3000 1 1 2x3x8 1 2 260 0 118 0 Stock 2 30 002002 RA3000 2x3x8 1 2 316 0 126 4 Stock 2 30 002004 RA3000 3x4x8 1 2 344 0 156 0 Stock 2 30 002006 RA3000 4x6x8 1 2 390 0 177 0 Stock Miscpart RA3000 1 5x3x10 Stock 5 20 000400 Small Pump Guard Stock 5 20 000402 Large Pump Guard Stock 2 30 002218 4 Impeller Key 02 01 Stock 2 30 002219
5. Note The installation of a barometric stack regulator is recommended at all installations Note If the tank is located outdoors nitrogen is required Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 8 Note Non code tanks cannot be pressurized over 15 psig Warning High temperature thermal fluid steam and combustible vapors may be vented through the vent connection on the combination dearetor thermal buffer expansion tank Warning Once the system has been filled any modification to the tank or connected piping requires purging of the work area to prevent ignition of potentially flammable vapors Consult factory prior to beginning work Consult MSDS for your thermal fluid for flammability limits Note If the circulating pump motor is not supplied by Fulton Thermal Corporation the motor starter will not be supplied Note Low emissions burners for all models require 10 psi gas pressure With the exception of the duct run previously described horizontal sections of ducting must be avoided and should not exceed four feet total Note The system pump is not to be used to fill the system Caution For reasons of safety the hot exhaust gas duct and chimney must be insulated or shielded within the locality of the heater Caution During operation any leaks
6. A pump that has been used for water or a different thermal fluid should not be used prior to extensive cleaning Thermal fluid can be damaged by contact with moisture or other fluids Warning Pressurizing a drum to force fluid into the system is not recommended The drum can easily explode creating a hazard to personnel and equipment rain and Fill Connection d Filling Procedure 1 Fill the system slowly closing all opened bleed and drain valves as fluid reaches them 2 When the fluid reaches and flows from the expansion tank low level manual test connection begin slowing down the filling process 3 Close the low level connection and continue to fill until the liquid level switch closes After fluid appears in the low level connection only a small amount of additional fluid should be required Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 56 4 If fluid is observed coming from the expansion section high level manual test connection drain fluid from the tank until the level is between the liquid level switch and the high level connection 5 Filling is complete when the fluid has reached the lowest level in the expansion tank required to actuate the liquid level switch Check to see that the liquid level switch operates freely To confirm operation of the liquid level switch manually trip the liquid level switch Unit should shut down pump will stop 4 For Systems
7. A Tin Industries nN Fulton Vertical Coil Design Thermal Fluid Heaters Models FT C amp FT S Installation Operation and Maintenance Manual Serial Model Fulton Order Sold To Job Name Date i B A K Fulton Thermal Corp 972 Centerville Road Pulaski NY 13142 Telephone 315 298 5121 Facsimile 315 298 6390 www fulton com Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 1 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 2 Table of Contents Section 1 Safety Warnings amp Precautions Section 2 Installation 90 NEON ANS eB G02 ING a Component View Placement Location Approximate Floor Loadings Minimum Make Up Air Access Circulating Pump Combination Thermal Buffer Tank Pressurized Systems Connections 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Conditions Pipework Systems General Equipment Piping Gasket Installation Piping System Connections Heater Connections Gauges Valves Testing Insulation Thermal Fluids Section 3 Operation 1 Start Up Preparation amp Installation Review Preparation Filling the System 13 14 15 16 17 18 19 20 21 22 For Systems Equipped with Inert Blankets Circulating Pump Initial Start Up Start Up Service Cold Circulation Filtering the System Firing t
8. Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer 16 Gasket Installation Instructions Lubricate nuts bolts and washers with a graphite oil mixture Assure that the flange surfaces are clean and free from damage Center gasket properly over flange In retrofit use pry bar to spread flange apart enough that the gasket will not be damaged when sliding in place Install all flange nuts and bolts Hand tighten Utilizing a torque wrench tighten all bolts to 20 final torque specification following a star pattern This means do not tighten bolts in order as a clock This will result in a poor seat between 12 o clock and 1 o clock Tighten all bolts to 40 final torque specification following a star pattern Tighten all bolts to 60 final torque specification following a star pattern Tighten all bolts to 80 final torque specification following a star pattern Tighten all bolts to 100 final torque specification following a star pattern Following a sequential pattern ensure that all bolts are tightened to 100 final torque specification It is important that all bolts are checked and re torqued after flanges have been heated and cooled down for the first time Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 40 Bolting Sequence for 4 and 8 Bolt Flanges Fulton Thermal Corp Vertical Coil Thermal
9. Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 22 e Alignment f Lubrication g Seals h Air Cooling Proper alignment directly affects bearing coupling and seal life expectancy The pump is properly aligned before it leaves the factory Because the system expands in operation pump must be realigned when the system is at operating temperature The coupling alignment of the pump and driver must be carefully checked for angular and axial alignment Check pump manufacturers instructions for these specifications The use of a dial indicator to check the axial and angular alignment is recommended An air cooled pump does not have an oiler This type of pump has a sleeve bearing which is like the seals lubricated by thermal fluid An air cooled pump has a grease nipple located at the drive end of the pump near the coupling connection This comes pre greased and should be greased at intervals as recommended by the manufacturer An oiler is shipped with each water cooled pump and it should be filled with a lubricating oil recommended by the manufacturer The suggested lubricant is usually SAE 30 non detergent oil Thermal fluid is not sufficient lubrication for bearings All seals on air cooled pumps are lubricated by thermal fluid therefore the pump must never be run dry i e without thermal fluid in it Filling a pump equipped with either a Grafoil packed or mechanical seal with thermal
10. 2 30 000332 300 Steam Gauge 5 23 Stock Strainer Parts 2 30 000870 60 Mesh Strainer Basket 2 Keckley A 18 Stock 2 30 000871 60 Mesh Strainer Basket 2 1 2 Keckley 38 17 Stock 2 30 000872 60 Mesh Strainer Basket 3 Keckley 66 3 Stock 2 30 000873 60 Mesh Strainer Basket 4 Keckley 15 34 Stock 2 30 000847 60 Mesh Strainer Basket 6 Keckley 15 34 Stock 2 30 000829 60 Mesh Strainer Basket 8 Keckley 8 37 Stock 2 12 000120 Gasket for 2 Keckley Strainer 04 02 Stock 2 12 000121 Gasket for 2 1 2 Keckley Strainer 04 02 Stock 2 12 000122 Gasketfor3 Keckley Strainer i o 0 2 Stok 2 12 000123 Gasket for 4 Keckley Strainer 14 06 Stock 2 30 000878 Gasket for 6 Keckley Strainer 14 06 Stock 2 30 000830 Gasket for 8 Keckley Strainer 14 06 Stock 2 30 000627 Strainer 4 Keckley 150 Flanged 62 2 28 3 Stock 2 30 000874 Strainer 5 Keckley150 Flanged amp Sok 2 30 000875 Strainer 6 Keckley 150 Flanged 68 5 34 3 Stock 2 30 000828 Strainer 8 Keckley 150 Flanged 999 0 454 0 Stock 2 30 000808 Strainer 2 2 Titan 2 30 000809 Strainer 3 Titan 2 30 000810 Strainer 4 Titan 2 12 000135 Gasket for 2 2 Titan Strainer 2 12 000136 Gasket for 3 Titan Strainer 2 12 000137 Gasketfor 4 Titan Strainer n S Ee TS Notes SIHI amp Allweiler pump flanges use 150 4 bolt Deans pump flanges use 300 Fulton Thermal Corp Vertical Coil Thermal Fluid M
11. 12 Impeller Bolt 04 02 Stock 2 30 002220 12A Impeller Washer 14 07 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 148 2 30 002221 13 Mech Seal Gland 1 8 9 Stock 2 30 002222 25A Thrust Bearing 1 5 Sf Stock 2 30 002223 28 Bearing End Cover 5 7 2 6 Stock 2 30 002224 29 Pump Shaft 9 5 4 4 Stock 2 30 002225 31 Thrust Bearing Locknut 3 2 Stock 2 30 002226 31A Thrust Bearing Washer 1 05 Stock 2 30 002227 75 Snap Ring 02 01 Stock 2 30 002228 76 Grease Seat front 1 05 Stock 2 30 002229 76A Grease Seat rear 1 05 Stock 2 30 002230 77B Bearing End Cover Gasket Stock 2 30 002231 95 A B Mech Seal 23 Stock 2 30 002232 180 Radial Bearing Cartridge 3 8 18 Stock 2 30 002233 325 Seal Gland Gasket Stock 2 30 002257 Seal Gland 1 week 2 30 002258 Lip Seal 1 week 2 30 002259 Gland Gasket 1 week 2 30 002256 Collar amp Set Screws 1 week 2 30 002252 6A Casing Ring 1x3x8 1 2 amp 1 1 2x3x8 1 2 Consult factory 2 30 002253 6A Casing Ring 2x3x8 1 2 Consult factory 2 30 002254 6A Casing Ring 3x4x8 1 2 Consult factor 2 30 002255 6A Casing Ring 4x6x8 1 2 Consult factory 2 30 002234 325A Seal Gland Gasket Stock 2 30 002242 365 Mech Seal Retainer 2 Al Stock 2 30 002251 3 Impeller 1x3x8 1 1 week 2 30 002235 3 Impeller 1 1 2x3x8 1 2 8 7 4 0 Stock
12. 2 30 002236 3 Impeller 2x3x8 1 2 10 3 4 7 Stock 2 30 002237 3 Impeller 3x4x8 1 2 11 1 5 1 Stock 2 30 002238 3 Impeller 4x6x8 1 2 12 6 5 8 Stock Miscpart 3 Impeller 1 5x3x10 Stock 2 30 002239 77 Casing Gasket 04 02 Stock 2 30 002240 6322595 Grease 2 A Stock 8 00 000046 Shaft Sleeve Guide 1 0 05 Stock 8 00 000047 Carbon Sleeve Removal Tool 1 6 8 Stock Dean s kits 4 30 000130 Start Up kit for Deans RA3000 Series Pumps Stock 4 30 000140 1 Year Service Kit for Deans RA3000 1 5x3x8 5 Stock 4 30 000141 1 Year Service Kit for Deans RA3000 2x3x8 5 Stock 4 30 000142 1 Year Service Kit for Deans RA3000 3x4x8 5 Stock 4 30 000143 1 Year Service Kit for Deans RA3000 4x6x8 5 Stock 4 30 000150 2 Year Service Kit for Deans RA3000 1 5x3x8 5 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 149 4 30 000151 2 Year Service Kit for Deans RA3000 2x3x8 5 Stock 4 30 000152 2 Year Service Kit for Deans RA3000 3x4x8 5 Stock 4 30 000153 2 Year Service Kit for Deans RA3000 4x6x8 5 Stock SIHI Un mounted Pumps includes impeller call for impeller trim size 2 30 001000 ZTN 3216 w mech seal 58 0 26 36 Consult factory 2 30 001002 ZTN 3220 w mech seal 84 0 38 18 Consult factory 2 30 001004 ZTN 4016 w mech seal 73 0 33 18 Consult factory 2 30 001006 ZTN 4020 w mech seal 84 0 38 18 Consult factory 2 30 001007 ZTN 5013 w mech seal 90
13. Automatic Fluid Control Valves 1 Because of the widely varied processes Fulton Thermal Fluid Heaters are used in it is not possible to set down specific rules for the selection of automatic fluid control valves Generally these valves must satisfy the materials and construction requirements described above 2 The type of operation and design of porting are governed by the degree of control required as well as the particular application Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 46 k Bypass Valves 1 When process flow requirements do not match heater flow requirements a by pass valve must be installed 2 Ifthe process flow will vary with the system load a suitable bypass system can be recommended by Fulton Thermal Corporation 22 Testing a Upon completion of the installation a pneumatic test not exceeding 15 psig should be conducted Soap tests should be made at all welds and joints to ensure that the system is free from leaks Under no circumstances should the system be filled with water Make sure that the air supply is as free from moisture as possible The most satisfactory method of testing is to introduce bottled nitrogen through a pressure control valve Check pressure ratings on all the equipment in the system to make sure that it is capable of withstanding the pressure involved The time needed to be spent during boilout directly corresponds to the amount of moisture in t
14. Pump bases 5 30 005000 12 x40 Base Stock 5 30 005002 15 x48 Base Stock 5 30 005004 18x48 Base Stock SAFETY RELIEF VALVES Thermal fluid safety valves 2 30 000544 Kunkle Safety Valve 34 100 psi 920 3 92 1 78 Stock 2 30 000545 Safety Valve 1 100 psi 920 5 72 2 6 Stock 2 30 000546 Safety Valve 1 1 4 100 psi 920 8 6 3 91 Stock 2 30 000547 Safety Valve 1 1 2 100 psi 920 15 04 6 84 Stock 2 30 000548 Safety Valve 2 100 psi 920 Stock Thermal fluid safety valve flanged 2 30 000609 Kunkle safety valve 34 100 psi 920 300 flanged 11 3 5 2 Stock 2 30 000610 Kunkle safety valve 1 100 psi 920 300 flanged 14 6 6 7 Stock 2 30 000611 Kunkle safety valve 1 1 4 100 psi 920 300 flanged 23 5 10 7 Stock 2 30 000612 Kunkle safety valve 1 1 2 100 psi 920 300 flanged 34 0 15 5 Stock 2 30 000613 Kunkle safety valve 2 100 psi 920 300 flanged 45 0 20 5 Stock Above used on heater 3117C amp Up 2001 Kunkle N2 safety valves expansion tank 2 30 000637 1 SRV 15 PSI 2 30 000636 3 SRV 15 PSI 2 30 000639 1 SRV 15 PSI 2 30 000638 1 SRV 15 PSI SKID COMPONENTS Worchester Valves 2 30 000534 V4 Threaded Ball Valve 1 54 07 Consult factory 2 30 000536 3 Ball Valve Two Way 1 98 9 Consult factory 2 30 000537 1 Ball Valve Two Way 3 82 1 74 Consult factory 2 30 000538 1 1 4 Ball Valve Two Way 5 1 2 32 Consult factory 2 30 000539 1 1 2 Ball Valve Two Way 7 46 3 39 Consult fa
15. a The combination expansion deaerator thermal buffer tank shall have gallon capacity and be supplied complete with liquid level switch It shall be suitable for a maximum total system fluid content of gallons including heater and expansion deaerator tank capacities based ona expansion rate of the hot oil to be verified by the client 6 Combination Expansion Deaerator Thermal Buffer Tank Design a The combination expansion deaerator thermal buffer tank will be constructed of carbon steel It shall be supplied with expansion tank liquid level switch and 300 ANSI flanged connections The tank may be built to ASME Code Section VIII Division upon request 7 Thermal Fluid Circulating Pump Size a The thermal fluid circulating pump shall be air cooled with mechanical seal design for 650 F maximum operating temperature GPMat PSI HP Motor RPM motor complete with motor starter voltage Water cooled pumps will be supplied upon request or for operating temperatures above 650 F 8 Thermal Fluid Circulating Pump Design a The thermal fluid circulating pump shall be of centrifugal design with a mechanical seal air cooled for temperatures up to 650 F or water cooled for operating temperatures above 650 F and shall be supplied complete with motor starter for proper motor HP voltage and cycles 9 Tests a Shall include a hydrostatic test of the pressure vessel in the presence of an inspector having a National Boar
16. in Section 5 Fuel oil piping should be done in accordance with local national requirements In addition if a two pipe system is employed a check valve should be fitted into the return pipe See fuel pump cut sheet 10 The maximum pressure allowed at the fuel oil pump inlet is limited to 3 psig by the National Fire Protection Association NFPA If for some reason the pressure of the fuel supply will exceed this maximum fitting a regulator to the fuel line must be considered e g when there is a tank situated with an oil level eight feet or more above the pump 11 On units fitted with NFPA 85 controls ignition is obtained by means of a gas pilot A natural gas or LP supply is required for these units The required gas supply pressure is 7 w c If a guaranteed supply of natural gas is not available then a supply of bottled gas at 11 w c is required For details contact a local liquid propane dealer Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 33 Typical No 2 Oil Fired Fuel Train Illustration 1 4 COPPER TUBING TO LOW PRESSURE OIL SWITCH ON CONTROL PANEL OILS S O V 0 400 PSIG SUPPLY gt PUMP INLET BURNER 3 8 COPPER TUBING MOUNTED MOUNTED TO TOSKID TOP OF UNIT lt RETURN RETURN TO TANK N BURNER MODULATING OIL VALVE Pr 0 200 PSIG ea IF APPLICABLE 1 4 NPT CHECK VALVE aS NC OIL VALVE 3 8 COPPER PRESSURE TURING INDICATO
17. it will be necessary to re align the circulating pump first at ambient temperature and again when it s at operating temperature d Cavitation of the circulating pump 1 Cavitation occurs when a partial vacuum presents itself at the eye of the pump impeller due to loss of head or if any low heater flashes to gas at the impeller During this time the pump impeller spins without actually circulating any thermal fluid If Fulton Thermal Corporation provided the heater skid loss of head to the pump is extremely unlikely with proper fluid level in the tank The most common low heater in a thermal piping system is water which needs to be boiled out at startup Once the system has been brought up to full operating temperature assuming that the entire system has seen flow there should be no further occurrence of low heater contamination apart from heat exchanger failure e Plugged coil pipe s 1 If too low of a flow condition has occurred for too long a period of time or if the maximum operating temperature of the oil has been exceeded it is possible however unlikely that a pipe or pipes in the coil could plug with solids If this occurs it will be necessary to shut down the system and clean the coil Fulton Thermal Corporation should be consulted in this matter f Improper switch setting Call For Heat 1 The Differential Pressure Switch should be set at operating temperature The setting should be 2 psi below t
18. manufacturer s specifications for dimensions of water cooling connection 2 The throttling valve on a water cooled pump is designed to automatically give the proper flow rate for a 40 PSIG or greater supply 3 Ifa minimum of 40 PSIG is not available consult Fulton Thermal Corporation about resizing the orifice If the temperature of the cooling water is greater than 55 F to begin with a correspondingly greater flow rate is required 4 For automatic operation of water cooling wire a solenoid valve on the inlet to open whenever the pump motor starter is energized Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 24 5 The outlet flow from the pump must not be restricted in any manner Therefore valves are not to be installed on the outlet Check local codes regarding disposal of hot water Typical Water Cooled Pump 8 Combination Expansion Deaerator Thermal Buffer Tank a Fulton Thermal s efficient design combines the operation of the expansion deaerator and thermal buffer tanks Installation is considerably simplified by virtue of this arrangement b Expansion Section 1 The expansion section is vital to the thermal fluid system From ambient to operating temperature the thermal fluid in the system will typically expand in the range of 30 and a vessel capable of handling this expansion is mandatory The customer should confirm the expansion rate of the chose
19. must be piped to a catch tank The discharge flow must not be restricted i e no valve should be installed The weight of the piping must be properly supported in order to prevent damage to the safety valve If the valve body becomes warped leakage may result Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 44 20 Gauges a The range in which readings are expected to fall should comprise mid scale on the pressure gauge chosen Pressure gauges must be able to withstand overpressure equal to the rating of the safety relief valves normally 100 psig Thermometers should read up to 650 F 21 Valves a Vent and drain valves should normally be 1 2 or 3 4 with internal seals made from materials suited to use with thermal fluids They may be of the screw type if installed on stalks not less than 12 long Gasketing material specifically suited to the task must be used Drain valves should be fitted at all low points in the pipework system and ventilating valves should be fitted at all high points in the installation Valves must be fitted with either the conventional packed stuffing box seal or a bellows seal as required Where the stuffing box is specified it should be as Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 45 deep as possible and packed with Grafoil packing or equal The valves should have a backseating to allow re packing without draining th
20. 0 40 91 Consult factory 2 30 001008 ZTN 5016 w mech seal 90 0 40 91 Consult factory 2 30 001010 ZTN 5020 w mech seal 95 0 43 18 Consult factory 2 30 001012 ZTN 6516 w mech seal 92 0 41 82 Consult factory 2 30 001014 ZTN 6520 w mech seal 89 0 40 45 Consult factory 2 30 001016 ZTN 8016 w mech seal 107 0 48 64 Consult factory 2 30 001018 ZTN 8020 w mech seal 115 0 52 27 Consult factory 2 30 001019 ZTN 10020 w mech seal 152 0 69 09 Consult factory SIHI Impellers 2 30 000589 8020 30 Impeller 210 mm 8 08 3 67 Consult factory 2 30 000590 5016 30 Impeller 170 mm 3 56 1 62 Consult factory 2 30 000591 3220 30 amp 4020 Impeller 210 mm 5 52 2 51 Consult factory 2 30 000693 5020 30 Impeller 210 mm 6 14 2 79 Consult factory 2 30 000694 4016 30 Impeller 170 mm 3 94 1 79 Consult factory Miscpart 10020 Impeller Consult factory Pump serial numbers must be given to factory to verify availability amp pricing Common parts for the following models 3213 3216 3220 4013 4016 4020 5013 5016 5020 6513 6516 6520 and 8016 4 30 000108 Mech seal kit 3213 to 8016 1 7 8 Stock 4 30 000110 Pump repair kit w mech seal 3213 to 8016 2 0 1 0 Stock 4 30 000100 Radial seal kit 3213 to 8016 1 34 61 Stock 4 30 000120 Pump rebuild kit w rad seals 8213 to 8016 2 32 1 05 Stock 2 30 001013 Item 500 Mechanical Seal 2 0 1 1 Stock 2 30 000580 Item 341 Sleeve Bearing 44 2 Stock 2 30 000583 Item 200 Shaft includes 25
21. 000262 LPJ40 Amp Stock 2 45 000261 LPJ50 Amp Stock 2 45 000260 LPJ60 Amp Stock 2 45 000382 LPJ70 Amp Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 141 2 45 000343 LPJ80 Amp Stock 2 45 000374 LPJ100 Amp Stock 2 45 000270 LPJ125 Amp Stock 2 45 000271 LPJ150 Amp Stock 2 45 001000 FNQ2 Amp Stock 2 45 000381 FNQ3 Amp Stock 2 45 000998 FNQ4 Amp Stock 2 45 000995 FNQ5 Amp Stock 2 45 000272 200 Amp Fuse Block Stock 2 45 000244 Fuse Block J600 603C Stock 2 45 000344 Fuse Block J60100 3CR Stock 2 45 000006 SC 40 Fuse 240V A 05 Stock 2 45 000007 SC 50 Fuse 240V A 05 Stock 2 45 000008 SC 60 Fuse 240V A 05 Stock 2 45 000276 16 Amp Disconnect Stock 2 45 001050 25 Amp Disconnect Stock 2 45 001051 40 Amp Disconnect Stock 2 45 001052 60 Amp Disconnect Stock Gaskets amp Material 2 60 000114 Silicone Sealant red 10 oz 82 37 Stock 2 60 000111 Silicone Sealant clear 10 oz 82 37 Stock 2 12 000010 Anti Seize 76764 1 0 5 Stock 2 60 000007 Turbo 50 4 oz 4 16 Stock 2 12 000052 Graphoil Packaging 5 23 Stock 2 12 000060 Kast o lite 30 55 per bag by the pound 55 0 25 0 Stock 2 12 000210 Va Rope Gasket Stock 2 12 000051 3 8 Rope Gasket Stock 2 12 000003 Ye Rope Gasket Stock 2 12 000049 1 Thermal Bar Gasket for burner plate Stock 2 12 000150
22. 001016 Air Servo to Air Gate Coupling 5 20 000435 End Bracket 2 required O amp M Manuals 5 60 000120 Coil Model Thermal Fluid Heater Manual C Model 5 5 2 5 5 days 5 60 000122 Vertical Tubeless Thermal Fluid Heater Manual A Model 5 days 5 60 000123 Electric Thermal Fluid Heater Manual N Model 5 days 5 60 000121 Unfired Steam Generator Manual 5 days PANEL BOX COMPONENTS Air Switch 2 30 000260 1910 5 Air Switch replaces 2 30 119 1823 2 Filter 1 46 66 Stock 2 30 000270 1910 0 Air Switch replaces 2 30 230 1823 1 Fan 1 46 66 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 145 Ignition Transformer 2 40 000082 6kv 120V 60hz Ignition Transformer 8 62 3 92 Stock 2 40 000084 6kv 110V 50hz Ignition Transformer 8 62 3 92 Stock 2 40 000086 10kv 120V 60hz Ignition Transformer 8 62 3 92 Stock 2 40 000088 10kv 110V 50hz Ignition Transformer 8 62 3 92 Stock Lights Switches Button Relays 2 40 000131 General Purpose Relay Ice Cube 700HA32A1 120V AB Stock 2 40 000135 General Purpose Relay Ice Cube 7OOHA32A2 220V AB Stock 2 40 000096 Base for Ice Cube Relay 1 Stock 2 40 000843 4 Pole Relay 120V AB 2 40 000842 4 Pole Relay Bast Stock 2 40 000993 PS5 RA24 power supply 4 2 Stock 2 45 000050 Fuel Selector Switch 34 15 Stock 2 45 000091 SPST Switch mod lock 05 02 Stock 2
23. 0929 Page 65 Required Pressure Drop Across the Heater Recommended Recommended Pressure GPM GPM Drop Model Schedule 40 Schedule 40 PSI FT 0080 C 44 50 25 FT 0120 C 66 75 27 FT 0160 C 88 100 20 FT 0240 C 132 150 30 FT 0320 C N A 250 25 FT 0400 C 220 250 25 FT 0600 C 330 375 26 FT 0800 C 440 500 26 FT 1000 C 550 615 18 FT 1200 C 660 730 27 FT 1400 C N A 800 27 FT 0400 S N A 400 18 FT 0600 S N A 600 16 FT 0800 S N A 800 19 NOTE The DP switch should never be set less than 2 psi below the required pressure drop 13 Burner Cycles Gas Fired Burners a b The burner is of forced draft cone design Pressure regulators on both the pilot and main gas supply supply pressure to the proper level Note the maximum inlet pressure rating of each regulator and supply a step down regulator if required Combustion air is delivered by a centrifugal blower fan An air switch monitors the pressure and is part of the flame programmer safety interlock circuit The flame programmer monitors the safe operation of the burner Functions include pre purge of the combustion chamber provision of ignition via the ignition transformer and electrode opening the pilot gas valve monitoring the pilot flame signal via the flame sensor opening main gas valves and providing post purge of the combustion chamber Ignition of the pilot gas must result in a stable pilot flame before the flame programme
24. 14 0 1 2 days 2 30 00301 1 24 M amp MG2 Barometric Control 66 0 60 0 2 30 003012 28 M amp MG2 Barometric Control 93 0 42 2 1 2 days BURNERS Gas Burners 7 30 004000 Complete FT 0080 C Gas Burner Less Pilot Tube 28 5 12 95 Stock 7 30 004001 Complete FT 0120 C Gas Burner Less Pilot Tube 28 68 13 04 Stock 7 30 004002 Complete FT 0160 C Gas Burner Less Pilot Tube 28 88 13 13 Stock 7 30 004004 Complete FT 0240 C Gas Burner Less Pilot Tube 42 8 19 45 Stock 7 30 004005 Complete FT 0320 C Gas Burner Less Pilot Tube 42 8 19 45 Stock 7 30 004006 Complete FT 0400 C Gas Burner Less Pilot Tube 46 52 21 15 Stock 7 30 004008 Complete FT 0600 C Gas Burner Less Pilot Tube 205 0 93 2 Stock 7 30 004010 Complete FT 0800 C Gas Burner Less Pilot Tube 155 0 70 5 Stock Gas Burner Parts 2 20 000054 UL Style Electrode 0 36 0 16 Stock 2 20 000071 UL Style Flame Rod 0 4 0 18 Stock 2 45 000025 Electrode Terminal Female 90 Stock 2 45 000392 Flame Rod Terminal Male 90 Stock 2 45 000026 Bakelite Terminal Female Straight Stock 7 20 005000 Pilot Tube w Flame Rod 3 96 1 8 Stock 7 20 005002 Pilot Tube for U V new style 3 01 3 94 1 79 Stock 7 20 005004 Inner Pilot Assembly w UV new style 3 01 1 86 0 85 Stock 7 20 005020 Inner Pilot Assembly w Flame Rod 1 86 0 85 Stock 7 20 005030 UV sight Tube only new style 3 01 1 0 0 45 Stock 5 20 000810 Ground fins for Flame Rod 6 required Stock 7 20 005010 Pilot Casing Assembly Stock Fulton Thermal Corp Vertical Coil Thermal Fl
25. 1K 397 1710 ot 5 510 2690 2210 1245 981 629 355 610 379 32 1500 776 FT 2000 L 42 22 106 107 62 454 31 15 28 14 528 2550 1070 560 2690 2734 1590 1146 792 en oe 394 710 379 zs 38 2000 1134 FT 3000 L 42 26 140 115 70 454 33 6 Oe 154 28 18 1 793 3200 1070 660 3556 2924 1778 1146 843 e 252 394 710 481 2 38 3000 1451 FT 5000 L 32s 18 s 60 26 130 132K 77 54 1524 660 3312 3356 1969 1387 818 0 9 20 37 1 1321 5300 238 524 940 25 38 5000 1637 481 Inlet and outlet dimensions vary with installation All dimension are approximate Specifications subject to change without notice Dimensions given in inches and MM Capacities given in gallons and LITERS Weights given in pounds and KG Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 30 Max Full Wt 1314 596 2450 1111 4380 1987 5875 2667 8230 3733 11 610 5265 17 370 7895 n Electrical Connections 1 A wall mounted fused disconnect sized for the unit must be provided and fitted by the client contractor if a disconnect is not supplied on the panel 2 Fuses must be sized according to motor name plates and local electrical codes 3 H
26. 4 4 15 12 X 52 636 1314 510 325 1370 1540 865 676 424 305 115 108 380 329 20 20 200 289 596 FT 0500 L 26 16 74 66 37 29 19 14 6 11 18 14 X X 132 970 2450 660 405 1880 1692 940 752 502 355 150 290 460 379 20 20 500 440 1111 FT 1000 L 36 20 76 87 49 38 22 15 T 14 24 14 1 1 264 1350 4380 915 510 1930 2226 1245 981 565 380 202 355 610 379 25 25 1000 612 1987 FT 1500 L 36 20 106 87 49 38 24 17 8 14 24 14 1 1K 397 1710 5875 915 510 2690 2210 1245 981 629 445 203 355 610 379 25 32 1500 776 2667 FT 2000 L 42 22 106 107 62 454 31 24 8 15 28 147s 1 1 528 2550 8230 1070 560 2690 2734 1590 1146 792 610 216 394 710 379 25 38 2000 1134 3733 FT 3000 L 42 26 140 115 70 45 33 6 24 O s 15 28 18 s 1 1 793 3200 11 610 1070 660 3556 2924 1778 1146 843 610 252 394 710 481 25 38 3000 1451 5265 FT 5000 L 60 26 130 132x 77 54x 32 24 9 20x 37 18 1 1 1321 5300 17 370 1524 660 3312 3356 1969 1387 818 610 238 524 940 481 25 38 5000
27. 45 000212 3 Position Switch SqD 14 06 Stock 2 45 000300 NO Contacts for switch 04 02 Stock 2 45 000269 NC Contacts for switch 04 02 Stock 2 40 000791 Push Button Start SqD green A 05 Stock 2 40 000793 Push Button Stop SqD red A 05 Stock 2 45 000412 Green Light SqD 120V 08 03 Stock 2 45 000411 Red Light SqD 120V 08 03 Stock 2 40 000841 700HR Time Delay Relay for Circulating Pump 85 34 Stock 2 40 000134 Time Delay Relay Base Stock 2 45 000309 Primary Stand by Switch 2pos 14 06 Stock 2 40 000151 Time Delay 10 sec adjustable 2 45 000203 Bulb S amp S 02 01 2 45 000205 Green Lens only S amp S 02 01 K 2 45 000206 Red Lens only S amp S 02 01 i Consult Factory for Lead Time Motor Contactors 3 phase 120V coil Siemens 2 40 000878 3RT1015 1AK6 Contactor 7 amp 8 36 Stock 2 40 000567 3RT1016 1AK6 Contactor 9 amp 8 36 Stock 2 40 000642 3RT1017 1AK6 Contactor 12 amp 8 36 Stock 2 40 000643 3RT1025 2QB0 Contactor 17 amp 8 36 Stock 2 40 000644 3RT1026 1AK6 Contactor 25 amp 8 36 Stock 2 40 000646 3RT1035 1AK6 Contactor40 amp 8 36 Stock 2 40 000825 3RT1036 1AK6 Contactor 50 amp 8 36 Stock 2 40 000647 3RT1044 1AK6 Contactor 65 amp 8 36 Stock 2 40 000645 3RT1033 1AK6 Contactor 28 amp Stock 2 40 000631 3RT1046 1AK6 Contactor 95 amp Stock 2 40 000637 3RT1046 1AK6 Contactor Stock 2 40 000879 3RH1921 1LA11 Aux Contactor Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 146
28. 6 34 4 45 9 50 1 49 3 49 3 63 4 70 5 95 108 4 108 4 MM 803 873 1 165 1 273 1 252 1 252 1 611 1 791 2 413 2 753 2 753 C Overall Depth IN 46 2 60 6 60 6 66 6 80 6 80 6 88 1 107 75 135 1 152 9 152 9 MM 1 173 1 540 1 540 1 691 2 046 2 046 2 237 2 736 3 432 3 882 3 882 D Flue Outlet Diameter IN 10 10 10 12 14 14 18 20 20 22 22 MM 254 254 254 305 356 356 457 508 508 559 559 Recommended Vertical Stack Diameter IN 10 12 12 14 18 18 22 24 24 26 26 MM 254 304 304 356 457 457 558 609 609 661 661 Approximate Dry Weight LB 1 500 2 100 2 550 3 400 5 300 5 300 8 250 11 450 19 250 21 700 23 000 KG 700 950 1 150 1 550 2 400 2 400 3 750 5 200 8 750 9 850 10 455 Diagram for guidance purposes only Comprehensive details of dimensions connections etc for each model are given on product dimension data sheets available from Fulton Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 167 DUC TIN INDUSTRIES LIMITED COMPANY Head Office 6 16 Fourth Quater Tan Chanh Hiep Ward Dist 12 HCMC Rep Office 8 10 Nguyen Ba Tuyen Str Ward 12 Tan Binh Dist HCMC Tel 08 6297 3207 Fax 08 6297 3209 Hotline 0982 455 456 Email info ductin com vn Website www ductin com vn Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 168 TI Duc Tin Industr
29. Equipped with Inert Blankets a a o O oO S Follow the instructions listed under Filling The System Pay close attention to notes and warnings Inspect the system to be sure all valves are open and all drains are closed Open all high point air vents Do not pressurize the system with nitrogen at this point Inspect the liquid level switch and be sure the switch is functioning properly Begin filling the system Fill the system until the liquid level switch indicates there is oil in the expansion tank Pressurize the system slightly with nitrogen Leave the high point vent connections open as the nitrogen should be isolated from the vents by the oil in the system The pressure required in the system at this point is only 2 3 psi If too much pressure is applied the nitrogen will bubble through the oil and vent to atmosphere If this happens reduce the pressure Continue filling the system If liquid level switch is made be sure to observe the high point vents as oil is now entering the elevated portion of the pipe work As oil reaches the vent close it After all vents have been closed and you believe the system to be full stop filling Start the circulating pump as described under Cold Circulation Leave the fill equipment connected as cleaning the strainer may create the need for more oil in the system The final nitrogen pressure is determined by measuring the difference between the D A Tan
30. Fluid Manual Version 2009 0929 Page 41 Standard gaskets supplied by Fulton are JM Clipper Elastograph for operating temperatures up to 650 F Recommended Loads for JM Clipper elastograph 150 Gaskets SAE Grade 5 Bolts typical or Equal Nominal Flange Size Diameter of Bolts Preferred Torque Required per Bolt Inches Number of Bolts Inches Ft Lbs 1 2 4 1 2 30 3 4 4 1 2 30 1 4 1 2 30 1 4 1 2 30 1 4 1 2 30 2 4 5 8 60 2 Ve 4 5 8 60 3 4 5 8 60 4 8 5 8 60 5 8 3 4 100 6 8 3 4 100 8 8 3 4 100 10 12 7 8 160 Recommended Loads for JM Clipper elastograph 300 Gaskets SAE Grade 5 Bolts typical or Equal Nominal Flange Size Diameter of Bolts Preferred Torque Required per Bolt Inches Number of Bolts Inches Ft Lbs 1 2 4 1 2 30 3 4 4 5 8 60 1 4 5 8 60 1 4 5 8 60 1 4 3 4 100 2 8 5 8 60 2 V2 8 3 4 100 3 8 3 4 100 4 8 3 4 100 5 8 3 4 100 6 12 3 4 160 8 12 7 8 245 10 16 1 160 17 Piping a High point bleeds are to be installed at all high points in the system piping 1 2 x 12 nipples welded in the top of the piping with ball valves amp plugs attached are to be used b It will save a considerable amount of time during the cold filtration if the thermal system piping is cleaned prior to assembly c The mill scale the results of oxidation on the inside of the piping as wel
31. Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 14 Section 2 Installation 1 Component View Component View Features of the Fulton Coil Design Heater Fluid travels through a continuous closed loop system The fluid is pumped through the coils to the fluid outlet and continues on through the entire system to the users Fluid Outlet Top mounted burner with special cone design produces a narrow long flame By keeping the flame away from the inner row of coils it avoids high flux impingement on the coils Fluid Inlet Fulton coil design thermal fluid hot oil heaters are a 4 pass combustion design resulting in high efficiencies and low emissions All state of the art operating controls are located in one central control panel First Pass radiant Combustion air enters the burner fan inlet travels upward between the inner and outer jacket preheating the air before it enters the top mounted burner The hot gases travel down the full length of the vessel creating the first pass Second Pass convection The gases then travel back across the inner row of coils creating the second pass Third Pass convection The gases continue back down between the inner coil and outer coil creating the third pass Fourth Pass The last pass is upward between the outer coil and inner jacket to the flue outlet Combustion Air Entering Fan Inlet
32. Gas servo if needed Press Enter to select the servo Move the gas servo to its new position with the arrow keys Press Enter to confirm the new value Use the down arrow to move to the air servo setting if needed Press Enter to select the servo use the arrow keys to set the new value Press Enter to confirm this d Switch the ON OFF switch back to ON The heater will re start The light off point for main flame can be set at a higher input than low fire 3 Press Escape 6 times to get back to the main menu 4 You can observe the status of the burner by going to OperationalStat NormalOperation Verify that the flame signal on the display is great than 90 and check combustion Adjust the burner to match the test fire sheet for main burner ignition The procedure described in step 2c is used Once the ignition position has been adjusted properly you are ready to check the burner throughout its modulation range Press Escape twice to get back to the main menu c Setting Main Run Modulation 1 Upon releasing the heater to main run modulation step 3 the heater will drive to low fire It is necessary to set combustion through the entire range of modulation first to enable high fire to be reached Once high fire is achieved the incoming gas pressure can be set Fine tuning of the servo setting throughout the range should be performed only once high fire settings are confirmed Note If the burner lo
33. Honeywell 10 step sequencer 11 5 0 Stock 2 40 000904 120V 240V 10 step solitec sequencer 1 82 83 Stock Note Above replaces 5 Step Solitec Sequencer 120V 240V 2 40 000025 600V 60amp contactor 120V 2 5 1 14 Stock 2 40 000024 300V 60amp contactor 120V 2 3 1 05 Stock 2 40 000022 600V 60amp contactor 220V 2 5 1 14 Stock 2 40 000852 21KW 230V Element NEMA 4 amp 7 15 14 6 88 2 4 weeks 2 40 000850 21KW 380V Element NEMA 4 amp 7 15 14 6 88 2 4 weeks 2 40 000847 21WKW 415V Element NEMA 4 amp 7 15 14 6 88 2 4 weeks 2 40 000851 21KW 460V Element NEMA 4 amp 7 15 14 6 88 2 4 weeks 2 40 000848 21KW 575V Element NEMA 4 amp 7 15 14 6 88 2 4 weeks 2 40 000854 11KW 208V Element NEMA 4 amp 7 11 5 0 2 4 weeks 2 40 000845 11KW 230V Element NEMA 4 amp 7 11 5 0 2 4 weeks 2 40 000846 11KW 380V Element NEMA 4 amp 7 11 5 0 2 4 weeks 2 40 000853 11KW 460V Element NEMA 4 amp 7 11 5 0 2 4 weeks 2 40 000849 11KW 575V Element NEMA 4 amp 7 11 5 0 2 4 weeks Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 138 2 12 000068 Element gaskets 11KW 04 01 1 week 2 12 000069 Element gaskets 21KW 04 01 1 week 2 22 000173 2 1 2 element bolt all thread 04 01 Stock 2 35 000348 Nut 5 16 04 01 Stock 2 22 000046 Lockwasher 5 16 03 01 Stock FUEL TRAIN COMPONENTS Manual Gas Valves 2 30 000398 v
34. If your coil inspection indicates severe sooting the following procedure should be followed DaO OL ese TNE Drain fluid from the coil using a pump Remove the burner and lower access doors Wire brush coils and use compressed air where accessible Vacuum loose soot where accessible Reinstall the burner and lower access doors Fire the heater to roughly 300 F Remove the burner again and fill the heater with a water detergent or water caustic mix to the flue outlet The water to caustic mix should be at a ratio of 25 gallons to one pound of caustic soda The amount of caustic for each heater is as follows Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 98 Heater Size FT 0080 C FT 0120 C FT 0160 C FT 0240 C FT 0400 C FT 0600 C FT 0400 S FT 0600 S FT 0800 C ST 0800 S FT 1000 C FT 1200 C Pounds of Caustic Soda 1 1 1 2 ona fF A OQ 7 8 Stir the mixture occasionally and let the wash continue for at least one hour 9 To drain the heater pump out Rinse heater thoroughly when finished before reassembling heater 4 Safety Check Procedures Liquid Level Switch a Manually turn liquid level switch cam counterclockwise Micro switch will open contacts and control voltage will be lost Release cam and micro switch will make and control voltage will be restored Liquid Level Switch Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Versi
35. Ignition position before pilot ignition d 44 Ignition position after pilot ignition e 52 Ignition position after main burner ignition f 72 Air damper in the postpurge position g 76 Traveling to the FGR position if the unit is equipped with FGR Press Escape 4 times to get back to the main menu Under ManualOperation Setload change the load to 0 by using the arrow keys Press enter and verify the 0 has been acknowledged in the curr field 8 Press Escape once to get back to the ManualOperation menu Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 73 10 11 12 17 Under Auto Manual Off change the operation to Burner On by using the arrow keys Press enter and verify that Burner On is acknowledged in the current field Press Escape twice to get back to the main menu Turn the main burner switch to On position Increase the set point Under operation Heater set point go to set point W1 using the arrow key then press Enter Change the set point under new using the arrows and press Enter The new set point should appear under actual and displayed in degrees After several seconds the burner control will start its pre ignition phase and the blower will start You can observe the status of the burner by going to the main menu by pressing Escape then selecting OperationalStat NormalOperation The unit will purge then drive to the ignition p
36. Reset ignition settings to manual specifications c Inspect internal surfaces of the heater Inspect refractory for cracks Cracks larger than 1 4 wide will require repair or replacement of the refractory Inspect coil for sooting If soot is present it can be removed by utilizing a brush or compressed air for light sooting d Have combustion checked for efficiency e Review daily log sheets noting any deviations from the norm Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 97 Annually a Replace the ignition electrode s b If the unit utilizes a flame rod replace c Clean all strainers in the thermal fluid system Q Take a one quart sample of thermal fluid and return to the thermal fluid manufacturer for analysis iv Schedule to local Fulton representative or factory service technician to perform an annual preventative maintenance 3 Maintenance Procedures Lubrication a Different motor manufacturers recommend various intervals for lubrication schedules Load variations will dictate the frequency and amount of lubrication required b When developing your lubrication schedule consider the thermal fluid pump and all system pumps c If you have a thermal fluid circulating pump with a packed seal the condition of the pump packing should be checked regularly If fluid leakage increases tighten the packing 1 4 turn daily Soot Cleaning a
37. Ring 2 30 910 2 30 910 2 30 910 2 30 911 2 30 911 2 30 912 Cone w Outer Ring 2 30 909 2 30 664 2 30 664 230 665 2 30 670 2 30 666 Cone Spacer 2 20 185 2 20 184 2 20 184 2 20 184 2 20 184 2 20 183 Allen Head Screw 2 30 928 2 30 928 2 30 928 230 928 2 30 928 2 30 928 Orifice Plate 2 20 173 2 20 173 2 20 173 2 20 172 2 20 172 2 20 171 Orifice Spacer 2 20 178 2 20 177 2 20 176 2 20 175 2 20 175 2 20 174 Orifice Screw 2 30 918 2 30 918 2 30 918 230 918 2 30 918 2 30 817 Burner Tube Assembly 7 30 5000 7 30 5000 7 30 5000 7 30 5002 7 30 5002 7 30 5004 Burner Plate Assembly 5 52 4000 5 52 4000 5 52 4000 5 52 4004 5 52 4004 5 52 4006 Complete Burner Less Pilot 7 30 4000 7 30 4001 7 30 4002 7 30 4004 7 30 4005 7 30 4006 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 106 Burners Used for LE Heaters Maxon Optima Burner FT800 C through FT1400 C Maxon MPakt Burner FT320 C through FT600 C Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 107 6 Troubleshooting Flow Circuit Circulating Pump s a The flow circuit is the electrical circuit that enables the circulating pump s Your thermal fluid pump s will remain on until the flow circuit opens to disable the pump starter or the Off Pump Heat switch is turned to the Off position b Items in the flow circuit may include paddle type flow switches a high
38. amount of vapor Leaks should be attended to as soon as possible because under certain circumstances such as saturated insulation thermal fluid can ignite when exposed to air and heat If a fire does occur extinguish using CO2 foam or dry chemical DO NOT USE WATER h Selecting a Thermal Fluid 1 The selection of the thermal fluid most suited to your application is very important Factors to be considered include efficiency thermal stability adaptability to various systems and physical Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 48 properties including vapor pressure freezing point and flash and fire points 2 Heat transfer fluids of both mineral and synthetic origin have been specially developed to give thermal stability over a very wide range of temperature A wide variety of thermal fluids have been used successfully in Fulton Thermal Fluid Heater systems however your final selection should be made in conjunction with Fulton Thermal Corporation or the fluid manufacturer 3 The Fulton coil design heater is a fired heat exchanger and the safe control and monitoring of the thermal fluid temperature is of paramount importance 4 The safe maximum bulk temperature of the fluid must be strictly adhered to The safe maximum temperature of the fluid varies but a typical maximum for many types of mineral oil based fluids is 600 F 320 C 5 Special care must be taken when consulting
39. fluid will ensure lubrication However in order to be certain that all seals on an air cooled pump are coated with thermal fluid the pump must be bled Grafoil packings require a run in procedure Typically pumps with these seals are shipped with four or five rings installed and several rings loose These extra rings must be on hand for the initial run in procedure See manufacturer s instruction manual for this procedure Allow for free air flow around the entire pump casing at all times Max room temperature should be 100 F Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 23 3 Inno case should any part of the drive side of the pump be insulated 4 Max operating temperature for air cooled pumps varies by manufacturer Consult instruction manual to verify Typical Air Cooled Pump 1 2 NPT Discharge Gauge Connection 3 8 NPT Barrier Oil Discharge When Specified Fill Mech Seal Only 1 8 NPT 1 8 NPT Vent Grease Fitting Pumpage Leak Detection Mech Seal Only 3 8 NPT Bearing Grease Relief and Lip Seal Failure Detection 1 4 x 1 8 Keyway 1 2 NPT Casing Drain Suction When Specified i Water Cooling 1 A throttling needle valve should be installed on the inlet side of the water cooling passages and adjusted so that the outlet water is between 120 F and 160 F Typically this means a flow rate of 2 5 GPM at 40 F inlet temperature Consult pump
40. follow Place heater with clearances to unprotected combustible materials including plaster or combustible supports not less than the following 1 Heater Front 36 1m Heater Sides 18 5m Heater Rear 18 5m Flue Pipe 18 5m Heater Top 60 1 52m For burner removal Burners may weigh up to 550 Ibs 5m OT Br OS depending on the type and configuration Customer to provide adequate means of burner removal All heaters will also require a minimum clearance of 5 overhead for personnel access and burner removal In cases where the available height is insufficient a roof or ceiling trap might be considered Pipes should not be run within ten inches of any control cabinets or combustible material For UL listed units see the specification plate on the Fulton Thermal Fluid Heater for these clearances Verify that these clearances are acceptable with the local ordinances Fulton Vertical Coil design units need only sufficient headroom for burner maintenance However in the event of major overhaul involving coil removal clearance as detailed in the Minimum Clearance for Coil Removal chart will be necessary If this space is not available the Fulton coil design unit may be removed to another area for coil removal Provision must be made for suitable access to the top of the heater Larger models of the vertical coil design unit FT 0320C and above require an access ladder gantry to be provided by the custo
41. in handling heavy equipment The customer should examine the heater for any damage especially the refractories It is the responsibility of the installer to ensure all parts supplied with the heater are fitted in a correct and safe manner Warning Operating the heater beyond its design limits can damage the heater it can also be dangerous Do not operate the heater outside its limits Do not try to upgrade the heater performance by unapproved modifications Unapproved modifications can cause injury and damage Contact your Fulton dealer before modifying the heater Warning A defective heater can injure you or others Do not operate a heater which is defective or has missing parts Make sure that all maintenance procedures are completed before using the heater Do not attempt repairs or any other maintenance work you do not understand Obtain a Service Manual from Fulton or call a Fulton Service Engineer Warning Thermal Fluid Heaters have high temperature surfaces that if touched may cause serious burns Only competent and qualified personnel should work on or in the locality of a thermal fluid heater and ancillary equipment Always ensure the working area and floor are clear of potential hazards work slowly and methodically Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 7 WARNING If the information in this manual is not followed exactly a fire or expl
42. in any fired heater there exists a film temperature which is higher than the temperature of the bulk of the fluid Temperature controllers measure the bulk temperature and not the film temperature This must be taken into consideration when setting the temperature controls These approximate guidelines for temperature settings are not to override the system design parameters These instructions should be used with information from the system designer Manufacturer s literature on the temperature controller is provided in the last section of this manual Standard primary temperature control sensing point location for On Off and Modulating heaters is on the heater outlet When optional inlet location of the primary controls is specified the following instructions may still be used with some modification For instance when primary controls are located on the inlet the dead band range will be much narrower than on Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 85 heaters with outlet control In addition temperature changes will not be as immediately apparent 8 An indicating temperature controller is used to regulate the thermal fluid temperature Typically the indicating control is a thermocouple 9 The thermocouple is directly immersed in the thermal fluid in the heater manifold The setpoint of the controller is regulated by the keypad Pump Motor Starter Flame Fan Motor Progr
43. inlet pressure switch a low inlet pressure switch a high outlet pressure switch and a differential pressure switch c Low Inlet Pressure Switch 1 All C Model heaters have a Low Inlet Pressure Switch This is a normally open switch that closes with proper heater inlet pressure This switch is generally a mercury bulb type switch Mercury will rest towards the green cap of the mercury bulb in a made condition 2 The purpose of the Low Inlet Pressure Switch is primarily to protect the heater from a low flow condition The Low Inlet Pressure Switch should be set at 5 psi below normal heater inlet pressure as read at operating temperature assuming that none of the conditions mentioned below are true A tripped Low Inlet Pressure Switch is an indication of one of the following 3 If your Low Inlet Pressure Switch is not making check the following items d Plugged circulation pump strainer basket 1 A plugged strainer will result in a decrease of flow through the heater High vacuums developed from plugged strainers can also stress the seals of the pump causing the pump to fail 2 A Pump Suction gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning Generally this point is between 0 and 5 Hg 3 Ifthe strainer is plugged isolate the strainer and drain that section of piping being mindful of the temperature of the thermal fluid 4 Remove the strainer and clean with compressed air high press
44. is to prevent potential pilot or main flame failures due to back pressure buildup during ignition Any alternative stack arrangement must supply negative 02 to 04 water column The run in the total distance of stack ducting as measured in a straight line from the outlet of the heater to the outlet of the stack should not exceed 70 of the rise See diagram below Note With the exception of the duct run previously described horizontal sections of ducting must be avoided and should not exceed four feet total The stack chimney and any components associated with the stack such as heat reclaimers or assist fans must be constructed from material that is rated for a 1200 F operating temperature Adequate provision must be made for the support of the weight of the chimney and stack to avoid having a load imparted to the outlet connection of the heater Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 36 Typical Stack Arrangements Install Appropriate Weather Cap Minimum 6 Above Any Structure Within 30 Support As Necessary Total Rise This Distance gt Must Not Exceed 70 A A Of Total Rise Expansion Joints As Required Stagger Entrances Cleanout Cleanout Door Door 11 Conditions a The draft when firing should be negative and constant A reading of 02 to 04 inches w c negative
45. return pipe from the burner This gauge will indicate the variation of oil flow caused by modulation of the burner Gauge readings should be recorded at start up and checked periodically 19 Dual Fuel Burner Changing Fuel a c d The following instructions apply only to units supplied with dual fuel burners These procedures should be performed only when the fluid is cold unless sufficient safeguards are provided to prevent contact with hot fluid piping in the vicinity of the burner Set the fuel switch to Off and the heat selector switch to either Pump or Off Gas to Oil 1 Turn off the manual gas cocks in the gas train Remove the gas nozzle orifice assembly from the burner Install the oil nozzle assembly and attach the oil whips to the assembly Open all oil manual shutoff valves Oil to Gas 1 Turn off all oil manual shutoff valves Detach the oil whips and remove the oil nozzle assembly Install the gas nozzle orifice assembly and open the gas cocks in the gas train Reset the hi low gas pressure switch Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 81 2 Set the fuel selector switch to the proper fuel Restart unit normally 20 Operating Controls a The following specifications data equipment and operating descriptions apply to typical Coil Design units These sections are provided for general information purposes only and do not necessarily reflect the spec
46. strip Yokogawa Heater operation interlock with circulation pump Low differential pressure switch to shut down the pump and heater due to a low flow condition U E Thermal fluid temperature control Siemens High System Pressure Switch for Complete Shutdown Danfoss or Honeywell Low System Pressure Switch for Complete Shutdown Danfoss or Honeywell Expansion Tank Low Level Switch for Shutdown Square D Heater Outlet Pressure Gauge Ashcroft Heater Inlet Pressure Gauge Ashcroft Pump Supply Vacuum Gauge Ashcroft Flame safety relay Siemens Magnetic starters for burner and pump motors Three Position Selector Switch off oump on heater on Four Indicating Lights 1 Pressure amp Flow 2 Heat Demand 3 Main Flame 4 Alarm ASME Certified Safety Relief Valve Kunkle Model 920 Non fused disconnect Single source power connection The burner shall be manufactured and matched to the heater by the heater manufacturer to fully assure single source system responsibility The burner shall be forced draft and shall be an integral part of the heater but designed for easy removal and cleaning of the burner Burner control method shall be On Off 3 1 modulation Burner control shall be completely automatic including flame supervision fluid flow monitoring and heater cycling Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 160 5 Combination Expansion Deaerator Thermal Buffer Tank Size
47. the unit After the gas valves open during the ignition trial the low gas pressure switch will trip Reset the low gas pressure switch and flame programmer Open main gas valve prior to gas train and close gas valve between last actuated gas valve and burner Attempt to light the unit After the gas valves open the high gas pressure switch will trip Reset the high gas pressure switch and the flame programmer Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 102 5 Recommended Maintenance Schedule See log sheet Daily a Complete log sheet at least once per day Twice per shift of operation is recommended Log sheet is available from the Fulton Service Department or on the web at www fulton com b Make visual inspection of entire system for leaks Repair as soon as possible c Note any failures on flame programmer noting fault number fault code fault annunciation fault hour fault cycle and fault time d Check the exhaust for the presence of smoke If smoke is present contact Fulton Service Department 315 298 7148 or your local Fulton Thermal Representative Weekly a Check inlet gas pressure at beginning of gas train Appropriately scaled gauge should be installed to facilitate this b Check last elbow gas pressure at high fire and low fire and compare to Thermal Combustion Checklist filled out by start up technician Appropriately scaled gauge should be installed to facilitate this R
48. when the unit and stack are cold usually indicates sufficient draft When the unit is running and the stack is hot the draft should read 0 04 0 08 inches w c negative b The installation of a draft regulator by the client contractor is recommended at all installations This will help to maintain the required draft The placement of the draft regulator should be as shown in the diagram labeled Alternate Installation of Barometric Damper c To maintain a reasonable temperature in the heater area and ensure safety to personnel the section of chimney duct within the building should be insulated Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 37 Installation of Barometric Damper Alternate Installation of Barometric Damper X 3TO5 PIPE DIAMETERS ON EACH SIDE OF DAMPER Wrong or Improper Installations of Barometric Damper Right Wrong Minimum Less Than 1 Pipe 1 Pipe Diameter Diameter 12 Pipework Systems a Certain properties of thermal fluid including low surface tension make it necessary to pay particular attention to containing the fluid Good pipework system design welded construction proper flanging gaskets and other appropriate means of eliminating potential leakage must be employed Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 38 13 General a All components exposed to thermal fluid flow including pipe valves and screen
49. 0 000248 Remote mounting cable 23 Stock 2 40 000247 Remote display mounting bracket Stock Pressure Switches amp Transducers 2 40 003040 Danfos pressure switch w manual reset 150psi 2 40 003041 Danfos pressure switch w auto reset 6 50psi 2 40 000662 6NN54FIA SOR pressuretrol NEMA 4 1 62 13 Stock 2 40 000661 6R3 D5 SOR pressuretrol M R NEMA 4 2 1 95 Stock 2 40 000999 Pressure transducer 0 100psi Stock 2 40 000994 Pressure transducer 0 200psi Stock 2 40 000998 Pressure transducer 0 15psi Stock Stack Limit Switches 2 40 000688 1000 deg F stack limit 1 96 89 Stock 2 40 000697 1100 deg F stack limit 1 16 53 Stock 2 40 000731 1000 deg F stack limit NEMA 4 1 38 63 Stock 2 40 000866 1100 deg F stack limit NEMA 4 1 98 9 Stock Temperature Controls Limits Thermocouples 2 40 000861 UT 350 yokogawa 1 2 55 Stock 2 40 000862 UT350L yokogawa 1 16 55 Stock 2 40 000867 UT 550 04 RSP yokogawa 1 16 55 Stock 2 30 000900 Yokogawa window kit NEMA 4 Stock 2 40 000909 FUJI PYZ4 RAY 1 4V 5 23 Stock 2 40 000311 EZ relay Stock 2 40 000816 UE E54 Temp Limit A N models 1 66 75 Stock 2 40 000631 Watlow temp control 146E1602 3 0 1 37 Stock 2 40 000800 2 x 8 Thermocouple wire 16 07 Stock 2 40 000801 4 x 12 thermocouple N amp A models 2 09 Stock 2 40 000802 2 x 12 Thermocouple C models 2 09 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 137
50. 0 0800C dual fuel 9 A Stock 5 20 005502 FT 1000C FT 1200C Flame Cone T Stok 5 20 005508 Oil delivery tube assy 0400 1200C dual fuel 7 5 3 4 Stock 5 20 005523 Nozzle adapter used on 5 20 5508 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 134 5 20 005524 End cap used on 5 20 5508 Stock 5 21 005506 Gas supply tube assy 0400 0800C 31 5 14 4 Stock 2 20 000087 Orifice retaining collar 0400 0800C 1 7 8 Stock 5 20 003497 Flame Cone 0400C 13 3 6 1 Stock 5 20 005498 Dual flame cone 0600C Stock 5 20 005495 Dual flame cone 0800C Stock 5 20 005547 Gas orifice nozzle assy 0400 0800C 3 5 1 6 Stock 7 20 005526 Oil air mixing Nozzle weldment 0400 0800C 5 3 Stock 7 20 004015 Dual fuel pilot assy 0400 1400C 3 0 1 2 Stock 5 20 005535 Outer tube assy 0400 1400C dual fuel 1 0 46 Stock 5 20 005537 Inner tube assy 0400 1400C dual fuel 1 0 46 Stock 5 20 005540 Insulator 05 Stock 5 20 005541 Insulator 05 Stock 5 20 005538 Electrode cap Stock Miscpart Rod for electrode cap connector 02 2 Stock 2 12 000251 FT 0600C 0800C refractory 210 0 95 5 Stock 2 12 000250 Refractory FT 1000C 1200C Stock 7 20 005045 Scanner tube 0400 1400C Stock 5 20 005503 Sleeve 0400 1400C Stock 2 45 000390 Electrode nut 0400 1400C Stock 5 21 003000 Screen LoNox Stock FANS BLOWERS AIR GATE ASSEMBLY Blowe
51. 000599 Item 81 O Ring 0 Stock 2 60 000153 EP 2 Grease 10 14 4 61 Stock Pump motor coupling parts 2 30 000707 E4 24mm Rexnord Hub 1 8 82 Stock 2 30 000705 E4 1 1 8 Rexnord Hub 1 45 66 Stock 2 30 000706 E4 1 3 8 Rexnord Hub 1 22 55 Stock 2 30 000710 E4 1 5 8 Rexnord Hub 96 44 Stock 2 30 000708 E4 Elastomer Element 1 36 62 Stock 2 30 000704 E5 24 mm Rexnord Hub 2 84 1 29 Stock 2 30 001072 E5 32 mm Rexnord Hub 2 4 1 09 Stock 2 30 000712 E5 1 1 8 Rexnord Hub 2 52 1 15 Stock 2 30 000703 E5 1 3 8 Rexnord Hub 2 5 1 14 Stock 2 30 000702 E5 1 5 8 Rexnord Hub 2 14 97 Stock 2 30 000713 E5 1 7 8 Rexnord Hub 1 64 75 Stock 2 30 000714 E5 Elastomer Element 2 14 97 Stock 2 30 000716 E10 24 mm Rexnord Hub 4 08 1 85 Stock 2 30 001073 E10 32 mm Rexnord Hub 5 0 2 27 Stock 2 30 000718 E10 1 5 8 Rexnord Hub 3 4 1 55 Stock 2 30 000717 E10 1 7 8 Rexnord Hub 3 04 1 38 Stock 2 30 000711 E10 2 1 8 Rexnord Hub 3 5 1 59 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 151 2 30 000715 E10 Elastomer Element 2 86 1 3 Stock 2 30 000752 E20 1 1 8 Rexnord Hub Stock 2 30 000821 E20 32 mm Rexnord Hub 7 86 3 57 Stock 2 30 000823 E20 1 7 8 Rexnord Hub 7 86 3 57 Stock 2 30 000824 E20 2 1 8 Rexnord Hub 7 86 3 57 Stock 2 30 000822 E20 Elastomer Element 2 86 1 3 Stock
52. 0C on off 1 week 5 30 004271 FT 0120C modulated 1 week 5 30 004277 FT 0160C on off 1 week 5 30 004272 FT 0160C modulated 1 week 5 30 004273 FT 0320C modulated 5 30 004278 FT 0400C modulated 5 30 004274 FT 0240C modulated 1 week 5 30 004279 FT 0600C modulated Oil Cones amp Assemblies 2 30 000656 FT 0080C FT 0120C Flame Cone 3 0 1 36 Stock 2 30 000657 FT 0240C Flame Cone 3 62 1 65 Stock 5 30 000657 FT 0240C Oil Flame Cone with Outer Ring amp Refractory 3 days Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 133 2 30 000658 FT 0400C Flame Cone 4 38 1 99 Stock 5 30 000658 FT 0400C Oil Flame Cone with Outer Ring amp Refractory 3 days 2 30 000659 FT 0600C Flame Cone 6 0 2 73 Stock 5 10 000495 FT 0600C Oil Flame Cone amp refractory assembly 1 week 2 30 000660 FT 0800C Flame Cone 100 455 Stock 2 20 000259 FT 0800C Oil Flame Cone amp refractory assembly 1 week 2 20 000053 Electrode FT 0080 0120 0160 0240 C 22 A Stock 2 20 000069 Electrode 2 p FT 0400 0600 0800C field straighten 24 11 Stock 2 20 000072 Electrode Holderfor2 20 69 24 41 Stok 2 20 000259 Electrode Holder for FT 0400 0600C Stock Oil Nozzles 2 30 000671 FT 0080C 5Gal 60 Degree Modulated Nozzle 04 02 Stock 2 20 000121 FT 0080C 5Gal 60 Degree on off Nozzle 06 03 Stock 2 30 000688 FT 0120C
53. 1 2 15 15 Fuel Consumption Full Output No 2 Oil GPH 7 1 10 7 14 3 21 4 28 35 3 53 69 7 87 1 104 5 122 LITER HR 27 40 6 54 1 81 108 8 136 201 263 7 329 6 395 5 461 5 Natural Gas FT3 HR 998 1 498 1 998 2 999 4 000 4 997 7 498 9 997 12 496 14 998 17 500 M3 HR 38 3 42 4 56 5 84 9 113 2 141 5 212 3 283 353 8 424 6 495 5 e Voltage 3 Phase for Burner and Pump Each unit has an incorporated stepdown transformer e Fuel up to No 6 Oil Available for Large Units e Efficiency up to 80 Minimum Based on High Heating Value of the Fuel No 2 Oil 140 000 BTU GHHV Natural Gas 1000 BTU ft3HHV Modulation 3 to 1 Turn Down Ratio Optional on FT 0080 0120 and 0160 Standard on all others e Circulating pump motor sizes based on standard pressure 55 PSIG and viscosity 1 cs specific gravity 0 7 with 25 37 PSID available head for installation Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 166 Dimensions Coil Design Thermal Fluid Heater Model FT C 0080 0120 0160 0240 0320 0400 0600 0800 1000 1200 1400 Heater Inlet Outlet Connections IN 1 25 5 2 2 51 3 3 4 4 6 6 6 MM 32 38 51 64 76 3 76 102 102 152 152 152 A Overall Height IN 73 7 80 7 80 6 89 7 100 6 112 4 143 6 143 146 5 146 4 163 1 MM 1 872 2 050 2 046 2 278 2 556 2 856 3 648 3 632 3 721 3 718 4 144 B Overall Width IN 31
54. 1637 7895 Inlet and outlet dimensions vary with installation All dimension are approximate Specifications subject to change without notice Dimensions given in inches and MM Capacities given in gallons and LITERS Weights given in pounds and KG Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 163 LOW LEVEL SWITCH LEVEL OF FLUID AT INITAL START COLD SEAL SECTION DEAERATION SECTION Developed specifically for thermal fluid system use the Fulton Combination Deaerator Expansion Thermal Buffer Tank is a patented design The unique combination of the operation of these three vessels in one results in numerous advantages including pipework simplification protection of thermal fluid from oxidation ease of installation and continuous deaeration of fluid avoiding pump cavitation Expansion Section The expansion section is vital to the thermal fluid system From ambient to operating temperature the thermal fluid in the system will typically expand in the range of 30 and a vessel capable of handling this expansion is mandatory Additional expansion section features include a liquid level switch and manual fluid levels test connections In the event of system fluid loss the level in the expansion section of the combination tank will drop and the liquid level switch will shut the unit down Manual low and high fluid level test connections are always provided De
55. 2 40 000532 UV 1A6 UV scanner 8 36 Stock 2 40 000531 Base for control 60 1466 2 5 23 Stock 2 40 000897 ED550 6 Cable 01 0 Stock 2 40 000808 Remote mounting kit 5 3 Stock 2 40 000804 ERT 1 rect Flame rod amp 2 40 000544 PPC 5000 control Honeywell Flame Programmer Controls amp Accessories 2 40 000262 RM7800M1037 Programmer 2 5 1 14 Stock 2 40 000264 RM7800L1038 Programmer 2 5 1 14 Stock 2 40 000260 RM7895A1030 Programmer 2 40 000265 ST7800A1013 7 Sec Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 136 2 40 000266 ST7800A1039 30 Sec A 05 Stock 2 40 000268 ST7849A1041 RM7800 amplifier flame rod 3 14 Stock 2 40 000269 T7849A1031 RM7800 amplifier UV amp 80 400C 2 09 Consult fact Miscpart Fuel air control R7999A1005 Stock 2 40 000273 ST7800A1098 RM7800 amplifier UV amp 600 1200C 2 09 Stock 2 40 000270 Base for RM7800 5 23 Stock 2 40 000272 Display module S7800A1019 5 23 Stock 2 40 000161 Mini peeper C7027a1049 UV scanner 5 23 Stock 2 40 000149 BC7OOOL Burner control Stock 2 40 000860 PM720L1030 Program Module 06 03 Stock 2 40 000157 Programmer R4140M 1210 5 0 2 27 Stock 2 40 000711 Programmer R4140L 1162 5 0 2 27 Stock 2 40 000713 Flame rod amplifer R7247A 1005 12 05 Stock 2 40 000160 UV amplifier R7249a1003 A 05 Stock 2 40 000159 Q520A Base 23 Stock 2 4
56. 2 Stock 2 12 000419 5 300 Gasket 54 25 Stock 2 12 000421 6 300 Gasket 6 27 Stock 2 12 000423 8 300 Gasket 65 3 Stock Modulation Parts 2 40 000722 Modutrol Motor M7284Q 1009 4 20Ma 9 88 4 49 Stock 2 40 000671 Modutrol Motor M9184C 1031 0 1350hm 6 5 2 95 Stock 2 40 000831 Modutrol Motor step transformer 220V 120V Stock 2 30 000499 CAS 500 Damper Crank Arm short A 05 Stock 2 30 000506 Superior Linkage Arms long 18 08 Stock 2 30 000507 Superior Linkage Swivels 06 03 Stock 2 40 000582 Adjustable Damper Arm 7 5 3 41 Stock 2 30 000335 Bearing Block 715 26 Stock 2 30 000839 Lock Collar Stock 2 10 000144 5 16 Linkage Rod Stock 2 10 000148 v2 Drive Rod Stock 2 45 000060 4 Handy Box Stock 2 30 003001 Rubber Linkage Boot Gummi Bellows NEMA 4 Stock 2 40 000200 Contactor R4242 120V Coil 27 Stock 2 40 000202 Contactor R4243 120V Coil 23 Stock Nexus Linkageless Modulation 2 40 000557 Flame Temperature Control Module 5 5 2 5 Stock 2 40 000558 Wiring Base 2 3 1 1 Stock 2 40 000574 Display Module 1 6 Stock 2 40 000553 NEMA 1 Servo NX04 2 2 1 0 Stock 2 40 000556 NEMA 4 Servo NX20 1 Stock 2 40 000811 Temperature Sensor 9 4 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 143 2 40 000571 220V Air Servo NX04 Stock 2 40 000572 220V Gas Servo NX04 2 Stock 5 20 000420 Small Servo Butterfly Valve Mounting Bracket Stock 5 20 000421 Small Servo Butterfly Valve Ad
57. 2009 0929 Page 59 7 Start Up Service a If start up service has been included in the order the factory should be contacted after the installation has been successfully completed and approved by the client s representative or engineers Where possible contact the factory at least one week before a Fulton service engineer is required on site All procedures covered in Operating Instruction sections Start Up Preparation and Filling the System including installation review air testing of piping pump alignment and filling the system must be completed before the service person s arrival Depending on the size of the system and the amount of service time contracted for start up service includes firing the heater boiling out the system checking verifying and adjusting all safety settings Careful preparation can expedite the commissioning of your heater Most delays can be avoided by following the instructions in this manual Failure to complete required procedures properly can result in the need for further service time at extra cost to the customer Service people will not commence start up if there are obvious system deficiencies However start up service in no way constitutes a system design check or approval of the installation In addition to commissioning the heater the service person will also familiarize heater room personnel with the operation of all Fulton equipment Personnel must be qualified to understand t
58. 22 2 amp gt This principle eliminates the need for large quantities of refractory resulting in low thermal inertia preventing overheating of the fluid in the event of pump power failure Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 15 2 Placement a Proper placement of your Fulton Thermal Fluid Heater is essential Attention paid to the following points will save a great deal of difficulty in the future Correct placement is the first step to trouble free installation operation and maintenance All Fulton Vertical Coil Design Heaters are shipped vertically and all units are crated for forklift transport Once uncrated all units with the exception of freestanding models FT 0080C FT 0120C FT 0160C and FT 0240C can be transported with a forklift These four models can only be lifted for unloading and moving by means of lifting lugs at the top of the heaters If means of lifting are not available rollers should be placed beneath the frame of the heater and it should be guided to the position of where it is to be installed Under no circumstances should weight be allowed to bear on the jacket control panel or fan housing of any Fulton Thermal Fluid Heater All stand alone heaters can be moved via a crane utilizing the lifting lugs on top of the heater The FT 0320C and larger stand alone heaters can also be moved using a fork lift All skidded units can be moved with forklifts 3 Lo
59. 3 2 8 3 4 150 4 8 3 4 150 5 8 3 4 150 6 12 3 4 150 8 12 7 8 240 10 16 1 368 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 43 18 System Connections a If screwed connections have to be made e g to items of control equipment then a thread sealant suitable for use with fluids at elevated temperature must be used Teflon tape standard pipe dope or hemp and paste are not acceptable Screw threads must be carefully and accurately cut If possible new tools should be used Threaded connections larger than 1 are not to be used It is recommended that GR5 or better tensile steel bolts be used for all flanged joints Note The system pump is not to be used to fill the system The system is usually filled from the lowest point with the aid of a pump On skid mounted units a drain and fill connection is provided in the inlet piping to the pump ain and Fill Connection 19 Heater Connections a b c The outlet of the pump should connect directly to the inlet of the heater via an isolating valve and pump flexible connector The heater outlet should be piped directly to the system via an isolating valve A safety relief valve may be shipped in the parts box accompanying the fuel fired heater and must be installed in the outlet manifold On all units the outlet must be piped to a safe discharge area The piping from the outlet of the safety valve
60. 53 Gas Valve Mounting Bracket 5 20 000455 Air Servo Mounting Bracket 5 20 000456 End Mounting Bracket Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 144 5 20 000426 80 320 400C End Mounting Bracket 5 10 004786 Gussett for Brackets 2 30 000804 Scanner Bracket Side View NEMA4 2 40 000436 Flame Detector Side View NEMA4 FT 0080C 5 20 00427 Linkageless Air Gate 5 10 001792 Air Gate Mounting Assembly 5 20 000456 End Bracket 2 Required 2 20 000422 Air Gate Servo Adapter 2 35 001016 Air Servo to Air Gate coupling 5 20 000455 Air Gate Center Bracket FT 120C 600C 5 20 000423 Linkageless Air Gate 5 20 000455 Air Gate Center Bracket 5 20 000456 End Bracket 2 required 2 20 000422 Air Gate Servo Adapter 2 35 001016 Air Servo to Air Gate Coupling 5 10 001702 Air Gate Mounting Assembly 5 10 001704 Air Gate Mounting Assembly FT 320C 400C Only FT 800C 5 20 000428 Linkageless Air Gate 4 20 000455 Air Gate Center Bracket 2 20 000422 Air Gate Servo Adapter 2 35 001016 Air Servo to Air Gate Coupling 5 10 001802 Air Gate Mounting Assembly 5 20 000457 End Bracket 2 required FT 1000C 1200C 5 20 000428 Linkageless Air Gate 7 21 000030 Air Gate Mounting Assembly 5 20 000455 Air Gate Center Bracket 2 20 000422 Air Gate Servo Adapter 2 35
61. 6 257 260 286 292 2 94 1 34 Stock 2 30 000585 Item 426 Rad Seal 7 required A 05 Stock 2 30 000451 Item 140 Gasket 01 0 0 Stock 2 30 000588 Item 81 O Ring 01 0 0 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 150 2 30 000594 Item 221 Ball Bearing Cover 23 Stock 2 30 000597 Item 230 Ball Bearing 23 Stock 2 30 000598 Item 292 Lockwasher 01 0 0 Stock 2 20 000190 Item 266 Spacer 01 0 0 Stock 2 12 000067 Item 80 13 Series Casing Gasket 12 05 Stock 2 12 000098 Item 80 16 Series Casing Gasket 18 08 Stock 2 12 000099 Item 80 20 Series Casing Gasket Stock 2 60 000153 EP 2 Grease 10 14 4 61 Stock Common parts for the 8020 and 10020 models 4 30 000112 Seal Kit w mech seal 1 7 8 Stock 4 30 000113 Pump Repair Kit w mech seal 4 1 1 9 Stock 2 30 001015 Item 500 Mechanical Seal 4 2 Stock 4 30 000102 8020 Seal Kit w radial seals 1 38 63 Stock 4 30 000122 8020 Rebuild Kit w radial seals 3 8 1 73 Stock 2 30 000451 Item 140 Gasket m4 0 0 Stock 2 30 000581 Item 230 Ball Bearing 98 45 Stock 2 30 000593 Item 221 Bearing Cover A 05 Stock 2 30 000582 Item 200 Shaft 7 5 3 41 Stock 2 30 000584 Item 426 Rad Seal 7 required A 05 Stock 2 30 000592 Item 241 Sleeve Bearing 66 3 Stock 2 12 000099 Item 80 Casing Gasket 0 Stock 2 12 000116 Item 80 Gasing Gasket for ZTN 10020 02 01 Stock 2 30
62. 8Gal 60 Degree Modulated Nozzle 06 03 Stock 2 30 000689 FT 0120C 8Gal 60 Degree on off Nozze 02 Stock 2 30 000673 FT 0160C 12Gal 60 Degree Modulated Nozzle 08 04 Stock 2 20 000122 FT 0160C 12 Gal 60 Degree on off Nozzle 08 02 Stock 2 30 000674 FT 0240C 17 5Gal 60 Degree Modulated Nozzle 06 03 Stock 2 20 000120 FT 0240C 17 5Gal 60 Degree on off Nozze 03 Stok 2 20 000200 FT 0320C 19 5Gal 60 Degree Modulated Nozzle 2 30 000675 FT 0400C 24 Gal 60 Degree Modulated Nozzle 06 03 Stock 2 30 000153 FT 0400C 35Gal 60 Degree Tip amp Disc 06 03 Stock 2 30 000676 FT O0600C 30Gal 60 Degree Modulated Nozzle 06 03 Stock 2 30 000158 FT 0600C 55Gal 60 Degree E180H Tip amp Disc A 05 Stock 2 30 000682 FT 0800C 85Gal 60 Degree E180H Tip amp Disc 12 05 Stock 2 30 000159 FT 1000C 100Gal 60 Degree E180H Tip amp Disc 12 05 Stock 2 30 000161 FT 1200C 120Gal 60 Degree E180H Tip amp Disc 12 05 Stock 5 10 003305 Inlet Outlet Block 6 3 Stock 2 30 000600 O ring for inner oil line Stock 5 20 004070 Inner oil line 1 05 Stock 2 30 G00010 3 8 Check valve Stock Dual Fuel Burner Parts _ _ OZ SSS O 7 30 004025 Complete FT 0400C Gas burnerless pilot tube dual fuel UV 124 0 56 4 Stock Scanner Tube 7 30 004026 Complete FT 0600 0800C Gas burnerless pilot tube duel Stock fuel scanner tube 7 30 004027 Complete FT 1000 12 C burnerless pilot tube duel fuel Stock scanner tube 5 20 005499 Air adjustment ring 040
63. Dresser Plate Gasket Material Omni light Stock 2 12 000140 Omnilight 8 OD Gasket Stock 2 12 000141 Omnilight 10 OD Gasket Stock 2 12 000142 Omnilight 12 OD Gasket Stock 2 12 000143 Omnilight 4 x9 Gasket Stock 2 12 000144 Omnilight 4 x14 Gasket Stock 2 12 000145 Omnilight 6x12 Gasket Stock Elastagraph Ring Gaskets for Flanges 2 12 000400 v 150 Gasket 22 Stock 2 12 000402 3 4 150 Gasket 44 Stock 2 12 000404 1 150 Gasket A 05 Stock 2 12 000406 1 1 4 150 Gasket 1 05 Stock 2 12 000408 1 1 2 150 Gasket 12 05 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 142 2 12 000410 2 150 Gasket 18 08 Stock 2 12 000412 2 1 2 150 Gasket 22 1 Stock 2 12 000414 3 150 Gasket 14 06 Stock 2 12 000416 4 150 Gasket 32 15 Stock 2 12 000418 5 150 Gasket 4 18 Stock 2 12 000420 6 150 Gasket 42 19 Stock 2 12 000422 8 150 Gasket 45 2 Stock 2 12 000401 1 2 300 Gasket 08 4 Stock 2 12 000403 3 4 300 Gasket 1 05 Stock 2 12 000405 1 300 Gasket 12 05 Stock 2 12 000407 1 1 4 300 Gasket 14 06 Stock 2 12 000409 1 1 2 300 Gasket 18 08 Stock 2 12 000411 2 300 Gasket 18 08 Stock 2 12 000413 2 1 2 300 Gasket 26 12 Stock 2 12 000415 3 300 Gasket 3 14 Stock 2 12 000417 4 300 Gasket 44
64. EMA 4 V4055D 1027 1574 745 Stock 2 40 000210 Fluid power actuator V4055A1130 220V 12 8 5 82 Stock 2 30 000310 1 Honeywell gas valve V5055A 1004 4 62 2 1 Stock 2 30 000311 1 1 4 Honeywell gas valve V5055A 1012 4 4 2 0 Stock 2 30 000312 1 12 Honeywell gas valve V5055A 1020 454 206 Stock 2 30 000313 2 Honeywell gas valve V5055A 1038 4 18 1 9 Stock 2 30 000315 2 1 2 Honeywell gas valve V5055A 4 86 Stock 2 30 000316 3 Honeywell gas valve V5055A 1053 9 7 4 41 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 139 2 40 000249 1 Honeywell V5055C 1034 5 0 2 27 Stock 2 40 000252 1 1 4 Honeywell V5055C1042 5 1 2 32 Stock 2 40 000253 1 1 2 Honeywell V5055C1059 6 0 3 0 Stock 2 40 000254 2 Honeywell V5055C1000 9 3 4 23 Stock 2 40 000163 2 1 2 Honeywell V5055C1018 10 5 4 77 Stock 2 40 000255 3 Honeywell V5055C1026 11 5 5 23 Stock Gas Pressure Switches 2 40 000533 High Low Gas Pressure Switch 2 16 1 6 3 25 1 48 Stock 2 40 000538 High Low Gas Pressure Switch 5 28 2 14 3 16 1 44 Stock 2 40 000539 High Low Gas Pressure Switch 10 50 6 24 3 14 1 43 Stock 2 40 000872 Ashcroft D428B Gas Pressure Switch Hi 2 8 1 27 Stock 2 40 000871 Ashcroft D429B Gas Pressure Switch Lo 2 78 1 26 Stock Ven
65. FT 0080 0120 0160 C Burner Plate 5 34 2 43 Stock 5 52 004004 FT 0240 0320 0400 C Burner Plate 9 7 4 41 Stock 5 10 002173 FT 0600 C Burner Plate Stock 5 10 002175 FT 0800 C Burner Plate Stock 7 30 005000 FT 0080 0120 0160 C Burner Tube 8 32 3 78 Stock 7 30 005002 FT 0240 0320 C Burner Tube 12 02 5 46 Stock 7 30 005004 FT 0400 C Burner Tube 13 32 6 05 Stock 5 30 004025 FT 0600 C Burner Tube 14 0 6 37 Stock 5 30 004030 FT 0800 C Burner Tube 15 0 6 82 Stock 5 30 004020 Burner Inlet Tee 8 44 3 84 Stock 2 30 000818 Burner Tee O Ring 0 01 0 0 Stock Cone Screws are required with purchase Orifice Screws are required with purchase Oil Burners and Parts 7 30 004020 FT 0080C 0120C 0160C Oil Burner less nozzle assembly 13 7 6 2 Stock 7 30 004023 FT 0240 C Oil Burner less nozzle assembly 29 4 13 4 Stock 7 30 004024 FT 0400C Oil Burner less nozzle assembly 37 6 17 1 Stock 7 30 004035 FT 0600C Oil Burner less nozzle assembly Stock 7 30 004038 FT 0800C Oil Burner Stock 2 20 000258 FT 0080C through FT 0320C Holder Electrode 2 30 000782 FT 0080 120 0160C Flame Spreader 0 44 0 2 Stock 2 30 000783 FT 0240 C Flame Spreader 0 46 0 21 Stock 2 30 000785 FT 0400 0600 C Flame Spreader 0 2 0 09 Stock 2 30 000786 FT 0800C Flame Spreader 0 9 0 41 Stock Oil Burner Nozzle Assemblies 5 30 004275 FT 0080C on off 1 week 5 30 004270 FT 0080C modulated 1 week 5 30 004276 FT 012
66. Manual Version 2009 0929 Page 156 ection 6 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 157 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 158 Section 6 Product Specs amp Data Fulton Fuel Fired Coil Design Thermal Fluid Heat Transfer Systems 1 General Description a Contractor shall furnish and install a fired BTU Hr thermal fluid heat transfer system The system shall be Fulton as manufactured by Fulton Thermal Corporation Pulaski New York The system shall be a complete package including a vertical coil design type heater combination expansion deaerator thermal buffer tank to allow for expansion of thermal fluid during heat up to operating temperature and to prevent oxidation of the thermal fluid during operation even when tank is vented to atmosphere for operating temperatures up to 650 F complete with instrumentation and controls as specified in Section 3 Flanged inlet and outlet shall be located at front end of the unit 2 Heater Size amp Operating Temperature a The heater net input shall not exceed ___ BT U Hr while producing a minimum of BTU Hr output as measured at the thermal fluid outlet The heater shall be supplied complete with control panel and all required safety devices for a maximum operating temperature of F standard 650 F max It shall have a flow rate of ___GPM and a motor voltage of with a control v
67. R FUEL MODULATING OIL PUMP OIL VALVE MOUNTING BRACKET Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 34 Typical Gas Fired Modulated CSD 1 Fuel Train Illustration FT 0320C and smaller Gas Safety The FT 400C has a similar layout Shutoff Valve HI LOW but uses two 2 gas safety Gas Pressure Switch shut off valves Butterfly Valve Main Gas Regulator Manual Gas 2 N P T Gas Connection Pilot Gas Valve Manual Gas Pilot Gas Valve Regulator Typical Gas Fired Modulated NFPA 85 Fuel Train Illustration FT 0600C and larger Pilot Gas Valves 2 N PT Gas Connection TIO amp i P SA ON N Pilot Gas A A A Manual Gas Regulator Valve HI LOW Gas Safety Gas Pressure Switch Shutoff Valve Manual Gas Regulator Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 35 q Stack amp Flue Connections 1 An appropriately sized stack should be connected to the flue gas outlet at the heater unit The stack should be the same diameter as the flue gas outlet for an FT 0080 C and at least one size larger for coil design models FT 0120 C and larger The stack should rise continuously to the connection of the chimney and should contain no more than two bends at 45 angles or less There should be two feet of straight horizontal flue before any change in direction fitting or draft regulator This
68. aerator Section At start up the primary purpose of the deaerator section is to remove all volatiles from the system to avoid pump cavitation The deaerator section also allows oxygen to be vented from the system on acontinuous basis during operation to avoid oxidation of the thermal fluid and removes other volatile particles generated by the fluid itself during system operation Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 164 Thermal Buffer Section A system of interconnecting pipework in the thermal buffer tank section prevents the movement of any oil that has not cooled sufficiently into the expansion section This avoids contact of very high thermal fluid temperature with oxygen contained in the atmosphere Sizing the Tank for the System Expansion tank capacity is the total volume of the tank It is necessary to have some air space available at the tope of the tank to avoid spillage or overflow At initial fill for system volume calculations the deaerator and cold seal sections must be filled completely and the expansion section must be filled to a level of 4 to make the low level switch The volume between the initial fill level and the safe full level is the amount available for expansion That volume is used to decide which tank is suitable for the system expansion Available for Capacity Initial Fill Expansion Max System Model Gallons Gall
69. ain ON OFF switch to ON Note As soon as a servo position is altered the servo will move to that position Only change servo settings by a maximum of 0 5 at a time before verifying combustion Caution The heater emissions may not be correct after changing the servo motor Verify the emissions throughout the range of modulation If emissions are off the servo motor can be adjusted by following the procedure in the Commissioning the Heater section of this manual Note Use extreme caution to avoid contact with the cleaning solution Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 11 Note Refer to local regulations for disposal of caustic solution Note All of the above maintenance procedures should be completed by trained personnel Appropriate training and instructions are available from the Fulton Service Department at 315 298 7148 or your local Fulton Thermal Representative Note Since unit lights at low fire it may be necessary to increase high gas pressure setting or jumper contacts to allow unit to modulate to where modulation gas valve back pressure is lessened Note Room temperature not to exceed 100 F Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 12 ection 2 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 13
70. ame programmer begins the cycle and the blower motor starts prepurge The air proving switch must be closed now Air dampers remain in maximum position Gas Pilot Provided all safety interlocks are proven ignition and pilot are energized and a timed trial for pilot ignition begins After the pilot flame is proven the main fuel valve is energized Ignition is turned off after main flame is established Spark Ignition Provided all safety interlocks are proven the spark is on and oil valves are opened When the flame is proven the spark is shut off When the fluid temperature reaches the setpoint of the operating temperature controller all fuel valves are closed The burner motor stops and the entire system is ready for restart on demand 18 Oil Fired Burner a The following refers to the design and operation of the on off burner utilizing fuel oil which requires no preheating This burner is of high pressure mechanical atomization design An oil pump is used to obtain necessary atomizing pressure before the fuel oil reaches the nozzle The fuel oil is divided into fine particles in the nozzle and imparted with a rotating motion before escaping from the nozzle as a cone of finely atomized oil Combustion air is supplied by a centrifugal fan A damper provides throttling of the inlet opening The air from the fan reaches the burner head after going through a turbulator accomplishing correct distribution and mixture of air and ato
71. ammer Air Starter Ignition Transformer j High Temperature Limit Switches Safety All units 1 All units are fitted with high temperature limit controllers which monitor the fluid temperature at the heater outlet This limit controller provides over temperature protection A high temperature limit switch acts as an over temperature safety Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 86 device If the high temperature limit shuts down the unit the manual reset button on the limit switch must be pressed The red button on the flame programmer must also be pressed to reset the unit before it can be restarted The high temperature limit controller is factory set to O F This must be set to the lowest of the following a Maximum operating temperature of the fluid b Maximum operating temperature of the equipment c 15 F over maximum system operating temperature Do not set this controller too close to the normal outlet temperature in order to avoid nuisance lockouts due to small transient over temperatures Several consecutive lockouts caused by the high temperature limit controller indicate the need for immediate installation review beginning with fluid level in the expansion tank firing rate and circulating pump performance k Operating Limit Controller 1 On Off Controls 1 The limit controller is mounted in the panel box door This limit controller senses temperature in the out
72. anual Version 2009 0929 Page 154 Standard Warranty for Fulton Thermal Fluid Heaters Warranty Valid for Models FT A FT C FT S FT N FT HC One 1 Year 12 Month Material and Workmanship Warranty The pressure vessel is covered against defective material or workmanship for a period of one 1 year from the date of shipment from the factory Fulton will repair or replace F O B factory any part of the equipment as defined above provided this equipment has been installed operated and maintained by the buyer in accordance with approved practices and recommendations made by Fulton The commissioning agency must also successfully complete and return the equipment Installation and Operation Checklists to Fulton s Quality Assurance department This warranty covers any failure caused defective material or workmanship Parts Warranty Fulton will repair or replace F O B factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one 1 year of shipment from the factory provided this equipment has been installed operated and maintained by the buyer in accordance with approved practices and recommendations made by both Fulton and the component manufacturers and the commissioning agency has successfully completed and returned the equipment Installation and Operation Checklists to Fulton s Quality Assurance department General Fulton shall be notified in writing as soon as any defect bec
73. apter Shaft Stock 5 20 000422 Air Gate Adapter to Servo Stock 5 20 000423 0120 0600C Linkageless Modulated Air Gate Stock 5 20 000424 Large Servo Air Gate Adapter Stock 5 20 000425 Air Gate Center Bracket for Mounting Servo Stock 5 20 000426 Air Gate End Bracket for Mounting Servo Stock 5 20 000427 0080C Linkageless Modulated Air Gate Stock 5 20 000428 0800 1400C Linkageless Modulated Air Gate Stock 5 20 000429 Large Servo Butterfly Valve Adapter Shaft Stock 5 20 000430 Large Servo Butterfly Valve Mounting Bracket Stock 2 45 000399 Current Monitor Relay Stock Miscpart Potentiometers Servo 61 6969 Stock Seimens Linkageless Modulation 2 35 001016 TAK Air Servo Adapter 2 35 001014 TAK Gas Servo Adapter 2 35 001018 TAK Oil Servo Adapter 2 40 000429 Plug Set 2 40 000430 Display Cable 2 40 000431 120V Transformer Power Supply 2 40 000432 Bus Cable End Clip 2 40 000433 Air Servo Motor 2 40 000434 Gas Servo Motor 2 40 000435 Conduit Adapter 2 40 000437 Display Module AZL 2 40 000447 Bus Cable 2 40 000449 120V Controller LMV51 2 40 000465 Flame Detector Self Check Vertical Mounting 2 40 000466 Infrared Scanner Bracket Vertical Mounting 2 45 001017 Black Nylon Cord Grip 2 20 000422 Air Gate Shaft Adapter 2 40 000458 220V Controller LMV51 2 40 000457 220V Transformer 2 40 000823 RTD 3 Wire 100 ohms 2 40 000767 58 1 Shaft 2 40 000768 33 9 Adapter 5 10 0030
74. are usually detected by a small amount of vapor Leaks should be attended to as soon as possible because under certain circumstances such as saturated insulation thermal fluid can ignite when exposed to air and heat Note Fulton Thermal Corporation cannot be held responsible in the case of accident or damage resulting from the use of inadequate fluid Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 9 Note Unless specially filtered compressed air will introduce moisture into the system Dry air or Nitrogen is recommended Note Some plastics can be dissolved by thermal fluid Note Do not use system circulating pump for system filling Note A pump that has been used for water or a different thermal fluid should not be used prior to extensive cleaning Thermal fluid can be damaged by contact with moisture or other fluids Warning Pressurizing a drum to force fluid into the system is not recommended The drum can easily explode creating a hazard to personnel and equipment Tanks are non code as a standard Non code tanks cannot be pressurized over 15psig Tanks built to ASME code Section VIII Div 1 are available upon request Note Do not run the pump before filling it with fluid Caution 1 Use extreme caution opening plug when system temperature is elevated Wear eye and hand protecti
75. art Also check differential pressure switch for proper operation and setting p The heater is over fired 1 If the heater has more fuel input than design it is probable that the heat transfer rate will increase beyond design Check input to heater at high fire for modulated heaters or at the standard rate for on off units This can be done by either using a corrected gas meter reading or measuring gas pressure supplied to the burner compared to factory test fire settings If input is improper inspect burner as described below If burner is not damaged or have improper components adjust fuel input and combustion to specification q Gas fired burner is damaged 1 Pull and inspect the burner Primary areas of concern for gas fired units are the orifice plate pilot assembly seating and orifice plate gap If the orifice plate is warped or burned through pilot assembly is not seated or gap between orifice plate and gas tube is improper more fuel than designed for will enter the furnace This will cuase the heater to have more fuel input than designed for The design flow rate will then be too low causing the fluid to heat up higher than it should r High Gas Pressure Switch 1 All gas fired modulating or IRI rated thermal fluid heaters have a High Gas Pressure Switch This is a normally closed diaphragm switch that opens on a pressure increase over set point The High Gas Pressure Switch is a safety device tha
76. at high temperature Generally temperatures below 150 F are acceptable to perform operation with regular work gloves With piping system cooled to ambient temperature torque all bolts on skid and throughout system to gasket manufacturer s specifications using proper flange torquing practices such as incremental torque increases star pattern etc Refer to Installation Section Visually inspect all thread fittings and valve packings Repair leaks and tighten valve packings to the point of stopping leak Upon putting unit back into operation check all gauge readings and compare to values given to you by the start up technician Note any discrepancies and contact Fulton 12 Required Pressure Drop Across the Heater a The thermal fluid pressure drop across your heater is critical This should be recorded at the completion of start up The pressure drop value is obtained by subtracting the heater outlet pressure from the heater inlet pressure when the thermal fluid is at normal operating temperature At the recommended standard flow rates and 7 sp gr the pressure drop across the heater should be as shown in the chart at the top right In the event of an abnormal reading contact Fulton Service immediately Failure to take immediate action in the event of reduced fluid flow may result in rapid and serious degradation of the fluid with possible damage to the heater Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009
77. auxiliary contacts are burned or pitted 1 Visibly inspect contacts With power off attempt to clean or replace starter if damaged Reset flame programmer and try to light unit again n High temperature limit 1 All thermal fluid heaters have at least one High Temperature Limit The high temperature limit s is are normally closed switch es that break on a temperature rise over set point The switch may be either a solid state controller or a bulb and capillary type switch The High Temperature Limit is a safety device that protects the thermal fluid and heat transfer coil from excessively high temperatures Solid state high temperature limits will have a manual reset Bulb and capillary type limits will not have a manual reset If this these switch es trips it is generally one of the following issues Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 119 o Flow rate is too low 1 Too low of a flow rate will result in a higher rate of heat transfer to the thermal fluid and heat transfer coils This will result in a higher temperature difference between inlet temperature and outlet temperature It is important to make sure that the minimum flow rate as specified by Fulton for that specific model is maintained Check inlet and outlet pressures of the heater to determine differential pressure and flow rate Ensure that this flow rate meets or exceeds minimums specified by Fulton see ch
78. bottom vent should be sized to allow a minimum of 0 4 square inch of opening for every 1 000 BTU hr input of fuel 10 cm 1000 kcal hr The upper vent should be at least one third this size See table for minimum make up air required and the recommended area of opening for each heater If positive forced ventilation is adopted you must ensure that there will be no appreciable pressure variation in the heater room Note The installation of a barometric stack regulator is recommended at all installations Artificial ventilation by extraction of air is not recommended This method of ventilation can create a negative pressure in the building which will seriously affect combustion and proper operation of the stack Please note that exhaust fans or similar equipment can create a down draft in the chimney or starve the burner s air supply Either case may result in poor combustion or nuisance failures A properly designed make up air system in the heater room will preclude these possibilities and is required to maintain proper combustion In addition an exhaust fan may draw products of combustion into the work environment creating a possible hazard to personnel It is essential that only fresh air be allowed to enter the combustion air system Foreign substances such as combustible volatiles and lint in the combustion system can create hazardous conditions When calculating ventilation requirements heat losses from the Fulto
79. burner should be pulled for refractory inspection A broken refractory should be cleaned out and replaced Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 126 Fulton Thermal Fluid Heater Log Sheet 7 y99y B07 1348 4 pin jewayy uona Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 127 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 128 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 129 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 130 Section 5 Parts amp Warranty Part Number Description Approx Weight Lead Ibs kgs Time Air Filter Box filters and air filter switch required 5 21 006625 Air Filter Box 0080C 1 20 x 20 filter required Stock 5 21 006617 Air Filter Box 45 6 20 8 Stock 5 21 006600 Air Filter Box Stock 5 21 006620 Air Filter Box 1 Week 2 30 000620 Air Filter 20 x20 x2 4 1 1 9 Stock 2 30 000621 Air Filter 24 x24 x2 5 1 2 3 Stock Barometric Dampers 2 30 000097 10 M amp MG2 Barometric Control 8 0 3 64 1 2 days 2 30 000098 12 M amp MG2 Barometric Control 12 0 5 45 1 2 days 2 30 000099 14 M amp MG2 Barometric Control 16 0 7 27 1 2 days 2 30 003010 18 M amp MG2 Barometric Control 31 0
80. cal representative or factory technician to perform preventative maintenance on the system Note All of the above maintenance procedures should be completed by trained personnel Appropriate training and instructions are available from the Fulton Service Department at 315 298 7148 or your local Fulton Thermal Representative Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 104 Oil Burner Assembly oH POTRODES 4 ELECTRODES 3 32 3 32 3 16 TYPICAL SECTION Model FT 0080 0080 01201 0240 0320 0400 w 6 1 8 Cone w 6 1 8 Cone 0160 A 2 3 3 15 16 3 11 16 3 5 8 3 9 16 B i 11 9 16 1414 15 17 11 16 Cc Ya a Ya Ya Ya a Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 105 Gas Burner Assembly Allen Set Screw Burner Inlet Plug o 2 22 000028 a 2 20 000156 A Pilot Tube O Ring 2 30 000818 Burner Tube 5 20 005110 Hex Head Bolt 1 4 20 x 1 Burner Plate Collar 2 22 000010 2 20 000157 Burner Tube Plate aag Glass Burner Plate Allen Orifice Head Screw Spacer 2 30 000926 Cone nico Spacer i Outer Orifice Ring Screw J Aon et Screw Pilot Tube A bl With UV Scanner Tube 2 30 024 7 20 005002 j rea oe it 230 000925 7 20 005000 Model FT 0080 0120 0160 0240 0320 0400 Outer
81. cation a Authorities with jurisdiction over any national or local codes which might be applicable to thermal fluid applications should be consulted before installations are made The heater should be located as close as possible to the place where the heat will be used in order to keep pipe work costs to a minimum A level hard non combustible surface is required for a suitable base for mounting the unit It is suggested that a four inch curb be installed completely around the unit In the event of a large spill this will help contain the fluid Approximations for the floor loading of each heater are given in the floor loadings table Check building specifications for permissible floor loading The heater should be placed in a suitable heater house or well ventilated separate room through which personnel do not normally pass This is not essential but the layout should eliminate traffic in potentially hazardous areas For instance the service engineer or the operator should not have to pass exposed hot pipe work to make adjustments to the heater controls Ventilation must be sufficient to maintain a building temperature of 100 F or less and the panel box temperature must not exceed 125 F Natural ventilation should be provided by means of grills at floor and ceiling level Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 16 To burn fuel properly the burner must have an adequate supply of air The
82. ck Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 140 2 40 000358 Hauck Oil Valve S39C 400 600C Stock 2 30 000502 Oil Valve normally closed S401AFO2V9BFS 1 88 85 Stock 2 30 000500 Oil Valve 220V 2 0 Consult factory 2 30 000698 Oil Valve 1 4 1500PSI 120V 9 2 4 2 Stock 2 30 000685 Oil Pressure Regulator RV3000 3 04 1 38 Stock 2 30 000497 Maxon Oil Valve W POC 1 2 28 0 12 8 Stock 2 30 000G10 Parker Check Valve 2 30 000780 Oil Pump Coupling L070 23 Stock 2 30 000033 Coupling Spider L070 23 Stock Fuses 2 45 000368 KTKR2 Amp Stock 2 45 000366 KTKR4 Amp Stock 2 45 000367 KTKR5 Amp Stock 2 45 000365 KTKR8 Amp Stock 2 45 000380 KTKR10 Amp Stock 2 45 000465 KTKR12 Amp Stock 2 45 000655 KTKR15 Amp Stock 2 45 000464 KTKR20 Amp Stock 2 45 000268 KTKR25 Amp Stock 2 45 000249 KTKR30 Amp Stock 2 45 000152 JKS30 Amp Stock 2 45 000010 JKS35 Amp Stock 2 45 000011 JKS40 Amp Stock 2 45 000012 JKS50 Amp Stock 2 45 000013 JKS60 Amp Stock 2 45 000214 LPJ 1 6 10 Amp Stock 2 45 000151 LPJ2 Amp Stock 2 45 000360 LPJ3 Amp Stock 2 45 000361 LPJ4 Amp Stock 2 45 000250 LPJ5 Amp Stock 2 45 000363 LPJ7 Amp Stock 2 45 000267 LPJ10 Amp Stock 2 45 000266 LPJ15 Amp Stock 2 45 000265 LPJ20 Amp Stock 2 45 000278 LPJ25 Amp Stock 2 45 000264 LPJ30 Amp Stock 2 45 000263 LPJ35 Amp Stock 2 45
83. condition through users Call or e mail Fulton for further details It may be possible that an automatic control valve has failed If this is the case the valve should be replaced b Plugged circulation pump strainer basket 1 A plugged strainer will result in a decrease in flow through the heater High vacuums developed from plugged strainers can also stress the seals of the pump causing the pump to fail A Pump Suction gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning Generally this point is 2 psi 5 in Hg Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 111 If the strainer is plugged isolate the strainer and drain being mindful of the temperature of the thermal fluid Remove the strainer and clean with compressed air high pressure water or a cleaning solution Replace and observe new heater inlet pressure c Failed circulation pump coupling 1 A failed coupling will result in a decreased or no flow condition through the heater The coupling can be checked by removing the coupling guard between the pump and pump motor The coupling should not be torn or misshapen If the coupling needs to be replaced it will be necessary to re align the circulating pump first at ambient temperature and again when it s at operating temperature d Cavitation of the circulating pump 1 Cavitation occurs when a partial vacuum presents itself at the
84. ctory 2 30 000540 2 Ball Valve Two Way 10 1 4 59 Consult factory 2 30 000897 2 Ball Valve w Actuator 7 08 3 22 Consult factor 2 30 000896 1 Ball Valve w Actuator 14 0 6 45 Consult factory 2 30 000899 1 1 2 3 Way Diverting Valve w Actuator 22 14 10 06 Consult factory Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 152 2 30 000898 2 3 Way Diverting Valve w Actuator 25 84 11 75 Consult factory 2 30 001300 1 1 4 Valve Repair Kit 16 07 Consult factory 2 30 001301 1 12 Valve Repair Kit 2 09 Consult factory 2 30 001303 1039 Actuator Repair Kit 18 08 Consult factory 2 30 001304 2039 Actuator Repair Kit 1 08 Consult factory 2 30 001305 Series 1039 Actuator 1 and smaller 06 05 Consult factor 2 30 001313 1 1 4 S Ring 02 03 Consult factory 2 30 001314 1 1 2 S Ring 02 01 Consult factory 2 30 001315 2 S Ring 01 Consult factory Dezurik Valves 2 30 000885 1 5 Dezurik Valve w El O Matic Actuator and Positioner Consult factory 2 30 000820 2 Dezurik Valve w El O Matic Actuator and Positioner Consult factory 2 30 000886 3 Dezurik Valve w El O Matic Actuator and Positioner Consult factory 2 30 000882 3 Dezurik Valve Repair Kit Consult factory 2 30 000880 2 Dezurik Valve Repair Kit Consult factory 2 30 000883 1 5 Dezu
85. ctory reading If there is a difference adjust modulating gas valve linkage Adjust for proper combustion throughout range u Gas orifice plate is warped 1 If above two items are proper check the pressure that the high gas pressure switch is sensing by way of a tee installed in the line Hold unit at low fire and check pressure Setting on switch should be 10 over pressure read Call Fulton if you have any questions v Gas pressure switch setting is improper 1 If above two items are proper check the pressure that the high gas pressure switch is sensing by way of a tee installed in the line Hold unit at low fire and check pressure Setting on switch should be 10 over pressure read Call Fulton if you have any questions Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 121 w Gas regulator has failed open 1 This is highly unlikely Regulators will usually fail safe in the closed position The gas regulator can be checked by checking upstream pressure and comparing to downstream pressure Make sure that the upstream pressure is not above the rating of the regulator Make sure that the downstream pressure does not exceed the range of the spring If regulator has failed replace reset input and adjust input throughout the range x Low Gas Pressure Switch 1 All gas fired modulating or IRI rated thermal fluid heaters have a Low Gas Pressure Switch This is a normally clo
86. ctured by Pittsburgh Corning Corporation or equal 24 Thermal Fluids Thermal Fluids at Elevated Temperatures a b 9 Plant engineers must be familiar with the nature of potential hazards when working with thermal fluids at operating temperatures Unlike steam or high pressure water systems thermal fluid attains extremely high temperatures without a corresponding increase in pressure While this lack of high pressure in the system yields many advantages a false sense of security should not be allowed to develop on account of this alone Certain types of thermal fluid may have operating temperatures reaching 650 F 345 C and above so all exposed pipework is hazardous and should be insulated as indicated in the preceding sections Flanged joints must be checked for tightness during and after the first warming up of the system After these checks exposed hot flanges pumps valves and fittings should be fitted with some sort of shield It is important to remember that there is pressure generated in the system by the circulating pump Great care should be exercised when opening any drain or vent valves in the system This is especially important during commissioning when any air trapped in the system is vented at high points and when water which will flash into steam is either expelled from the deaerator vent or drained off at low points Caution During operation any leaks are usually detected by a small
87. d Commission He shall certify a Data Report which shall be delivered with the heater as evidence of ASME Code compliance In addition to ASME symbol the heater shall bear a National Board Registration Number b Full electrical checks will be performed including testing of all controls and circuitry c Test fire with combustion check Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 161 10 Operating Manual a Instructions for installation operation and maintenance of the heat transfer system shall be contained in a manual provided with each unit b Acomplete wiring diagram corresponding to the equipment supplied shall be part of the manual and one shall also be affixed to the inside of the heater s panel box Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 162 Dimensions and Sizing Instructions of the Fulton Combination Expansion Deaerator Thermal Buffer Tank Models FT 200 L to FT 5000 L 2 c Combination Expansion Deaerator Thermal Buffer Tank 1 2C VENT a i 76 N2 REGULATOR S E k E v2 j TYP s 1 3 ety 50 8 ER TN er 1e F A la P N A SAFETY RELIEF eae O Tawna Hi SWITCH D CONNECTION COUPLING INLET DEAERATOR OUTLET MODEL G J L CAP Dry Max Full Ref Ref Wt Wt FT 0200 L 20 12 54 60 34 26 16 12
88. daptor Stock 2 30 000483 10 5 8 Mod air control O080C Air gate 4 0 1 8 Stock 2 30 000484 12 3 16 Mod air control 0120 0600C Air gate 5 12 2 32 Stock 2 30 000485 15 Mod air control 800 1400C Air gate 7 06 3 2 Stock 5 10 001792 Air pick up MTG plate FT 0080C 4 8 2 2 Stock 5 10 001702 Air pick up MTG plate FT 0120C 0600C 6 7 3 1 Stock 5 10 001802 Air pick up MTG plate FT 0800C 5 5 2 5 Stock 7 21 000030 Air gate assy FT 1000 1400C 18 2 8 3 Stock 2 21 000110 Motor mounting plate FT 0120 0160 0240C 4 0 1 6 Stock 2 21 000113 Motor mounting plate FT 0320C 4 0 1 6 Stock 2 21 000111 Motor mounting plate FT 0400 0600C 4 0 1 6 Stock CONTROLS Differential Flow switches 2 30 000454 UE H105K14727 differential pressure switch 4 0 1 82 Stock 2 30 000448 UE H105K456 differential pressure switch 2 20 psi 4 0 1 82 Stock 2 30 000453 4 needle valve block valve 1 0 46 Stock 2 35 000330 Swedgelock straight 025 Stock 2 35 000329 Swedgelock 90 degree 025 Stock 2 35 000526 Steel tubing union 2 10 000211 1 4 OD steel tubing 2 30 000813 Flow switch O ring shaft 001 0 0 Stock 2 30 000814 Flow switch O ring casing 001 0 0 Stock Fireye Flame Programmer Controls amp Accessories 2 40 000542 EP380 on off Module Stock 2 40 000545 E110 Burner control 5 1 2 32 Stock 2 40 000528 E120 Burner control 220v 5 6 2 55 Stock 2 40 000543 ED510 Display Module E120 amp E110 5 Stock 2 40 000806 EP170 Programmer 6 27 Stock 2 40 000540 EUV 1 UV amplifier 6 27 Stock
89. e ee Fuel oil pump may have lost its prime 1 An air bubble in the pump will result in a momentary loss of prime that will be enough to cause the Low Oil Pressure Switch to trip Ensure that oil pump is primed properly and all connections are tight Check the pump seal A blown seal will allow air in the pump housing ff Fuel oil pump motor may have failed 1 Check the pump motor for proper voltage If voltage is proper but motor does not turn replace or rebuild motor If there is no voltage check motor starter for input signal and incoming 3 phase power gg Fuel oil pump coupling may have failed 1 A failed coupling will result in the pump not turning Check coupling Replace if necessary Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 123 Pilot Flame Failure a e f A Pilot Flame Failure is a flame failure that occurs when the unit is trying to establish an adequate flame signal Solid state controllers indicate a Pilot Flame Failure by showing as a fault code either Fault 28 for Honeywell 7800 series controllers Flame Failure PTFI on Fireye E110 series controllers or Fault 9 on Fireye Nexus controls For electro mechanical controls you need to witness when the failure occurs A Pilot Flame Failure indicates that either a strong enough pilot flame was not generated or the means of sensing the pilot flame strength has failed All gas fired units have a gas pi
90. e FT 0320 C w ring 4 88 2 22 Stock 5 21 006518 Refractory Spider 0080 0160C 15 0 6 0 Stock 5 21 006519 Refractory Spider 0240C 20 0 8 0 Stock 5 21 006498 Refractory Spider 0320C 20 0 8 0 Stock 5 21 006499 Refractory Spider 0400C 15 0 6 0 Stock Miscpart Plywood form for top Refractory 12 0 4 8 Stock 5 10 000494 FT 0600C Gas Burner Tile 205 0 93 2 Stock 5 10 000492 FT 0800C Gas Burner Tile 120 0 54 6 Stock 2 20 000186 Orifice Spacer 035 FT 0080 C Nat Gas 3 total 0 02 0 01 Stock 2 20 000177 Orifice Spacer 052 FT 0120 C Nat Gas 3 total 0 02 0 01 Stock 2 20 000176 Orifice Spacer 0158 FT 0160 C Nat Gas 3 total 0 04 0 02 Stock 2 20 000175 Orifice Spacer 0140 FT 0240 0320 C Nat Gas 3 total 0 06 0 03 Stock 2 20 000174 Orifice Spacer 0200 FT 0400 0600 C Nat Gas 6 total 0 06 0 03 Stock 2 20 000216 Orifice Spacer 0235 FT 0800 C Nat Gas 6 total 0 06 0 03 Stock 2 30 000918 Orifice Screw FT 0080 0120 0160 0240 0320 C 3 total 0 04 0 02 Stock 2 30 000817 Orifice Screw FT 0400 0600 0800 C 6 total 0 04 0 02 Stock 2 20 000173 Orifice Plate FT 0080 0120 0160 C 1 84 0 84 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 132 2 20 000172 Orifice Plate FT 0240 0320 C 3 94 1 79 Stock 2 20 000171 Orifice Plate FT 0400 C 5 14 2 34 Stock 2 20 000170 Orifice Plate FT 0600 C 7 4 3 36 Stock 2 20 000217 Orifice Plate FT 0800 C 26 52 12 05 Stock 5 52 004000
91. e sure they remain stable In case of pressure fluctuations stop the burner but allow the pump to continue to circulate fluid When pressures have stabilized start burner again Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 63 i Continue in this manner up to the maximum operating temperature Throughout the initial warm up the expansion tank and its overflow pipe must be watched to detect the formation of steam indicating the presence of water If this occurs burner should be shut down If steam is forcing thermal fluid out of the expansion tank vent turn the heater off but leave the pump on This is to circulate the hot fluid through the piping without flushing the steam too quickly Once steam and thermal fluid stop leaving the expansion tank unit the heater can be turned on Increase the temperature very slowly to prevent fluid from being forced out of the tank Note Do not open drain or vent valves during operation Note If excessive amounts of thermal fluid is vented from the system additional thermal fluid may be required in the system Note Flash steam may be generated at any point up to the operating temperature Watch for gauge fluctuations Continue bringing unit up to temperature slowly with a temperature rise not exceeding 100 F 38 C per hour Do not exceed specified maximum outlet temperature In the absence of specific in
92. e system In all units a Y type strainer should be installed in the fluid return line between the deaerator tank and the circulating pump e As previously stated this strainer is provided on all skid mounted units Valves must be provided unless the heater has been skid mounted with the tank so that the strainer can be isolated for cleaning of the element The strainer element should be 60 mesh and must remain in place during normal operation of the system f The pump suction pressure should be checked periodically under similar operating conditions A vacuum reading on the suction gauge indicates that the screen must be cleaned For isolating purposes globe wedge gate ball or other shut off valves should be used When there is a likelihood that some manual balancing will be required a ball or globe valve should be used g Manual control and isolating valves should be the flanged or weld type manufactured from cast or forged steel or ductile iron with internals and gland seals made from materials suitable for use with high temperature fluids h When ordering valves the maximum possible service temperature and type of fluid must be indicated on the order i A partial list of manufacturers known to market valves of acceptable quality follows Jenkins Brothers Lunkenheimer Company Nibco Incorporated Stockham Valves and Fittings Company Velan Q3 TOI odes G04 I ae Vogt Machine Company 7 Worcester Valve Company j
93. e to the display If the base module fails in the future the display can be used to download all of the parameters into a new base module The heater is now ready to run Adjust your setpoint on the temperature control to the desired temperature and turn the main ON OFF switch to ON for the burner to operate f Before Leaving the Installation 1 2 Check all controls to insure they are operating properly Cycle the heater several times by raising and lowering operating temperature on the thermostat Make sure the installation complies with all applicable codes g Changing Set Point on the AZL 1 Hit ESC to Select Operation than hit enter and scroll to Heater Set point hit enter to Set point W1 hit enter and enter new set point with Select buttons Done hit enter than ESC 3 times to Operational Stats hit enter to Normal Operation hit enter to main screen h For Manual Operation 1 3 Hit ESC and scroll to Manual hit enter to Auto Manual Off change to manual and hit ESC to Set Load change to 0 or desired load range with the select buttons Done hit ESC and scroll to Operational Stats hit enter to Normal Operation hit enter to main screen To return back to Auto operation repeat step 1 amp 2 i Replacing a Servo Motor 1 If it is determined that a servo motor needs to be replaced the first step in this process is to verify the model number of the new servo motor is the same as the old
94. eadings should be within 0 2 w c Monthly a Clean fuel filters b Check blower fan Clean if necessary c Clean or change air filter if installed d Manually check fluid level in expansion tank e Check operation of all safeties Contact Fulton service department for instructions f When the unit is running disconnect the flame sensor Heater should shut off on flame failure immediately within 3 seconds g Review log sheets and note any deviations from the norm h Drain gal Of oil from thermal buffer section of DA tank Semi Annually a Pull burner and inspect for heat stress or soot Clean or replace if necessary b Inspect pilot tube assembly and ignition electrode Clean or replace if necessary Reset ignition settings to manual specifications c Inspect refractories for cracks Make sure there are no pieces of refractory loose on the bottom of the unit Cracks 1 8 wide can be patched If cracks are 1 4 or larger refractories need to be replaced d Review log sheets and note any deviations from the norm e Have combustion checked for efficiency Check coil for soot buildup Clean if necessary Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 103 Annually a b c d Replace ignition electrode Clean all the strainers in the thermal fluid system Take a quart sample of thermal fluid and have it analyzed per fluid manufacturers instructions Schedule the lo
95. eaters and single skid systems are generally shipped completely prewired The liquid level switch on the expansion tank when supplied will be shipped in the parts box and must be installed in the field Multiple skid systems may require wiring between the skids 4 Ifthe unit is not skid mounted at the factory the client contractor is required to wire the circulating pump starter Note If the circulating pump motor is not supplied by Fulton Thermal Corporation the motor starter will not be supplied o Voltage amp Frequency 1 Normal supply will be 460 volts 3 phase 60 Hz AC unless otherwise specified 2 Make sure the information on the electrical drawing corresponds to your voltage and frequency Check the supply voltage and make sure that there is no over or under voltage exceeding 10 of the nominal value The Fulton Coil Design Thermal Fluid Heater MODEL NO NATL BOARD NO O e JE E 7 c SERIAL NO MAX gt Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 31 p Fuel Connections Gas Connections 1 The burner assembly and gas controls terminate at a manual stop valve to which the gas supply should be connected Piping should be sized for a gas flow consistent with the required BTU Hr input Large pressure drops must be avoided Fulton Thermal Corporation recommends that the supply piping between the pressure regulator and the inlet to the heater be kept t
96. eave the parameter then use the Up key to advance through the option list To leave the Option parameters Press Data Run key then Press Com Enter key The engineers key is a hidden key under the Fireye logo on the display With the use of the engineers key it is possible to read the values of the internal system variables and external input and output states It is also possible to see the values of fault subsets in order to obtain more detailed information about a fault that has occurred After pressing the Fireye logo use the Up Down keys to move through the parameters When using the engineers key it is not possible to change any parameters To leave this screen press the Fireye logo and this will bring you out of the engineers parameters Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 70 3 The engineers key parameter list begins on page 55 in the Nexus manual e Nexus Fault Code Display 1 The Nexus 3100 uses the LED lights on the front of the control to provide diagnostic capability to enable the operator to identify faults when they occur The fault listing begins on page 52 of the Nexus manual Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 71 Oil Nozzle dual fuel burner Models FT 0600 C through FT 1400 C Complete dual fuel assembly Gas Nozzle with orifice dual fuel burner Models FT 0600 C through FT 1400 C Fulton Thermal Corp V
97. em has been filled any modification to the tank or connected piping requires purging of the work area to prevent ignition of potentially flammable vapors Consult factory prior to beginning work Consult MSDS for your thermal fluid for flammability limits c Combination Expansion Deaerator inc Thermal Buffer Tank VENT n 76 N2 REGULATOR I TYP F A i me a 60 8 j aie ea a a q A SAFETY RELIEF gt 4 N VALVE CONN LIQUID A f j LEVEL ee ee as LIQUID LEVEL ft g i a ag ae a palo i D CONNECTION Dl Vap EXPANSION TANK j L N if a y gt Fard l ESA eer DEAERATOR THERMAL H _ 1 2 w E BUFFER l 7 j DRAIN amp LIQUID LEVEL Ca ee EEn L A x iz b n Li aE J ic DRAIN L G H me Jl earner MODEL B Cc G J L CAP Dry Ref Ref Wt FT 0200 L 20 12 60 26 16 4 4h 15 12 X x 52 636 510 325 1370 1540 865 676 424 115 108 380 329 20 20 200 289 FT 0500 L 0 16 74 66 37 29 19 6 1 18 14 X x 132 970 405 1692 940 752 150 290 460 379 20 20 500 440 FT 1000 L 20 87 49 38 T e 14 24 14 1 1 264 1350 e 510 1880 2226 1245 981 een 202 355 610 379 25 25 1000 612 FT 1500 L 20 106 87 49 38 24 8 14 24 14 1
98. ertical Coil Thermal Fluid Manual Version 2009 0929 Page 72 16 Siemens Linkageless Modulation a Setting Pilot 1 Verify the main burner switch is in the OFF position 2 Supply power to the heater The AZL will display system test and them move to the main menu 3 Select PWLogin press Enter Select AccessServ Press Enter This type of step will be shown as PWLogin AccessServ for the remainder of this section Enter the service passwords using the arrow key The password is case sensitive The case of a letter can be changed by pressing the other arrow key For example if you used the right arrow key to get to the letter A press the left arrow key to get a After you have pressed Enter on the last character of the password press Enter once more to accept the password If you do not have the password contact your Fulton Authorized Representative to perform the changes Service NB or OEM AAAA Enter after each A 4 Select Params amp Display Press Enter Select Ratio Control Press Enter Select ProgramStop Press Enter Change the Program Stop to 44 Interv1 by using the arrow keys Confirm the change by pressing Enter This will set the burner management system to a pilot hold setting 5 Verify that the current value curr changes to 44 Interv 1 The full listing of program stops are a 24 Air damper in the prepurge position b 32 Traveling to the FGR position if the unit is equipped with FGR c 36
99. evel test connections are 1 2 NPT and are located on the end of the tank opposite the inlet The low level is on the center line of the expansion tank the high level is next to it slightly off center The high level rises up from the bottom of the tank and ends four inches below the top the low level rises two inches from the bottom of the tank Both the high and low level connections should be piped to a safe catchment Valves should be installed in these lines at the catch tank Installation of the valves should be accomplished in such a manner that any flow will be visible when the valves are open Flow from the high level test connection indicates a tank that is too full no flow from the low level test connection indicates too little fluid There is a 300 pound raised face flanged drain on the bottom of the thermal buffer section for the purpose of draining the tank when necessary This should be piped with a valve in the line to a safe catchment The valve specifications outlined above apply to this valve as well An inspection opening is located at the highest point on the tank Access to this port is recommended but not required Refer to the maintenance schedule for recommendations on draining the buffer tank For positioning of all connections on tank see the diagram labeled Combination Expansion Deaerator Thermal Buffer Tank Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 29 Once the syst
100. evice There is no manual reset on the air filter switch itself to indicate a trip The most likely time of an air filter switch trip is at high fire purge or high fire If this switch trips it is generally one of the following issues g The air filter is dirty 1 If the air filter becomes dirty the fan will generate greater suction Too much suction will result in not enough airflow for proper combustion and mixing and will cause air switch to trip You should regularly change filters on a schedule dependent on how dirty the makeup air is After checking or changing air filter reset the flame programmer and try to light unit again h There is an obstruction in the make up air ducting 1 Units that have make up air ducting need to assure that blockage to the ducting does not occur Check outside termination and any bends in the ducting for blockage Clear blockage reset flame programmer and try to light unit again i The sensing line is pointing in the wrong area 1 The sensing line for the air filter switch is supposed to provide the static pressure of the air box The termination of the sensing line should be pointing in a direction that limits its contact with moving air If the sensing line is pointing perpendicularly to entering air stream the switch will not sense the proper pressure and could give a false indication of air box suction Reset the flame programmer and try to light the unit again Fulton T
101. exchanger failure 1 Lack of back pressure If control valving is improper or pressure drop across the system is too low the resulting minimal back pressure may not provide enough resistance for the flow to make the pressure switch Check the thermal fluid system for proper operation of control valves h Blocked sensing line on pressure switch 1 A blocked sensing line will give an inaccurate pressure reading to the pressure switch A blocked line will need to be replaced or cleaned Most installations have block valves at the heater to facilitate safe isolation and cleaning of the sensing line Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 109 i Improper switch setting j Faulty Switch 1 1 The Low Inlet Pressure Switch should be set at 5 psi less than the pressure read on the heater inlet pressure gauge at full operating temperature of the system If pressure is verified and reads correctly above set point on switch and the sensing line to the pressure switch is open the pressure switch is faulty Replace switch set for desired set point and test for proper operation k High Outlet Pressure Switch 1 All C Model heaters have a High Outlet Pressure Switch This is a normally closed switch that opens with excessive heater outlet pressure This switch is generally a mercury bulb type switch Mercury will rest towards the green cap in a made condition The p
102. eye of the pump impeller due to loss of head or if any low heater flashes to gas at the impeller During this time the pump impeller spins without actually circulating any thermal fluid If Fulton Thermal Corporation provided the heater skid loss of head to the pump is extremely unlikely with proper fluid level in the tank The most common low heater in a thermal piping system is water which needs to be boiled out at startup Once the system has been brought up to full operating temperature assuming that the entire system has seen flow there should be no further occurrence of low heater contamination apart from heat exchanger failure e Plugged coil pipe s 1 If too low of a flow condition has occurred for too long a period of time or if the maximum operating temperature of the oil has been exceeded it is possible however unlikely that a pipe or pipes in the coil could plug with solids If this occurs it will be necessary to shut down the system and clean the coil Fulton Thermal Corporation should be consulted in this matter f High inlet pressure switch 1 Units newer than mid 1993 have a High Inlet Pressure Switch This is a normally closed switch that opens with improper heater inlet pressure Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 112 2 This switch is generally a mercury bulb type switch Mercury will rest towards the green cap in a made condition The purpo
103. f an appropriately scaled gauge Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 94 b Check manifold gas pressure at high and low fire and compare to Thermal Combustion Checklist filled out by start up technician This should be accomplished by the installation of an appropriately scaled gauge Readings should be with 02 w c of Thermal Combustion Checklist Monthly a Clean fuel filters b Check burner blower Clean if necessary c Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 95 d Manually check fluid level in the expansion tank Drain 1 2 gallon of thermal fluid from the expansion tank If water is present continue to drain 1 2 gallon until no water is present e Check operation of all safeties Refer to the instructions at the end of this section f With the burner running remove or disconnect the flame detection device The flame programmer should lockout within 3 seconds g Review daily log sheets noting any deviations from the norm h Check the tightness of all couplings including the fuel oil pump drive oil fired units fan impeller circulating pump etc Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 96 Semi Annually a Pull burner and inspect for heat stress or soot Clean or replace as necessary b Inspect pilot tube assembly and ignition electrode Clean or replace if necessary
104. f or has cracks in the porcelain replace with a new flame rod 3 Reinstall and cycle unit If the unit has a U V scanner lockout and tag heater s fuel supply Remove U V scanner from U V sight tube Make sure that the lens of the scanner is clean Use a Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 124 lighter or match and make a flame in front of the scanner eye Lens should flicker If unti does not flicker change U V scanner If this change does not work change U V amplifier Reinstall and cycle unit g Room air pressure is different from outside air pressure 1 Check room air pressure relative to outside air pressure Heater room pressure should equal outside air pressure Significant differences in pressure will result in an erratic flame which will not deliver a strong flame signal Main Flame Failure a Main Flame Failure is a flame failure that occurs while the unit is trying to establish an adequate flame signal during the Main Flame Trial for Ignition b Solid state controllers indicate a Main Flame Failure by showing as a fault code of either Fault 19 for Honeywell 7800 series controllers Flame Failure MTFI on Fireye E110 series controllers or a Fault 09 for Fireye Nexus controls For electro mechanical controls you need to witness when the failure occurs c A Main Flame Failure indicates that either a strong enough main flame was not generated or
105. fluid manufacturers literature as maximum fluid temperatures quoted are the actual limit to which any of the fluids may be subjected It is important to remember that in any fired heater there exists a film temperature which is higher than the temperature of the bulk of the fluid 6 It is the BULK fluid temperature and NOT the FILM temperature that is indicated by the instruments 7 As a general guide the following list of fluids that have given satisfactory service over many years is provided 8 This is by no means a complete list Any fluid specifically designed for heat transfer use may be considered multipurpose oils are not acceptable a AMOCO Transfer Oil 4199 b CHEVRON Teknifax c DOW Dowtherm A or G d EXXON Caloria HT 43 e MOBIL Mobiltherm 603 or 605 f MONSANTO Therminol g MULTITHERM PG1 IG4 IG1 h PARATHERM Paratherm NF or HE i PETROCANADA CalFlo AF Purity FG CalFlo LT j SHELL Thermia 23 k TEXACO Texatherm Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 49 9 10 Any fluid specifically designed for heat transfer use must also exhibit these characteristics a Be a stable and homogenous liquid to a temperature of at least 100 F over and above the maximum intended temperature of utilization compatible with metals used in the installation and tolerating contact with atmospheric air b The absence of any solid matter in suspension c No
106. formation consult the factory before proceeding Once up to temperature check the fluid level in the expansion section by opening the high level manual test connection If a permanent flow of fluid results when this valve is opened and if all previous precautions have been followed the expansion tank is too small for the capacity of the fluid in the installation A larger tank must be installed After fifty hours of operation at operating temperature check all flanges and connections for tightness Note Start up technician should verify that all valves are opened prior to establishing flow and heat up Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 64 Note If fluid or piping is added to the system the boil out procedure must be followed as water has to be introduced into the system 11 Procedure for First Shutdown a The heater system should be shut down after no more than 24 hours of operation at full operating temperature At this time the following maintenance items will need to be completed to meet warranty conditions While pump is still at operating temperature align circulating pump s to pump manufacturer s specifications This should be done by means of a dial indicator Isolate Y strainer s in system and clean regardless of pump suction pressure Make sure that the temperature is low enough to handle safely or provision has been made to handle materials
107. h Outlet Pressure Switch should be set at 5 psi over than the maximum pressure read on the heater outlet pressure gauge during proper operation at the coldest ambient temperature expected If pressure is verified and reads correctly below set point on switch and the sensing line to the pressure switch is open the pressure switch is faulty Replace switch set for desired set point and test for proper operation Units older than mid 1993 have Flow Switches on the inlet of each pipe in the coil These are normally open switches that close making a micro switch upon flow establishment The purpose of the Flow Switch es is to protect the heater coil from too high of a temperature and to protect the thermal fluid from exceeding its maximum film temperature Each flow switch is wired in series requiring flow through each pipe in the coil Flow Switches Not Making a An obstruction downstream of the Flow Switch es 1 Any obstruction downstream of the flow switch es will increase the pressure that the heater outlet sees Any increase in outlet pressure will result in diminished flow This obstruction will generally result from an improper valve setting Observe heater outlet pressure at temperature with all users heat exchangers calling for heat 100 user Observe heater outlet pressure at temperature with all users heat exchangers not calling for heat 100 bypass Bypass regulating valve s should be adjusted to equal flow
108. hat volume is used to decide which tank is suitable for the system expansion A system contains 175 gallons including the heater but not the tank You select the FT 200 L so you add 25 gallons to 175 You must look up the expansion rate for the thermal fluid Assume it is 25 200 gal x 1 25 250 gallons 250 200 50 gallon expansion The FT 200 L has only 46 gallons available for expansion so the correct selection is the FT 500 L The tank must be installed in accordance with Fulton Thermal Corporation s specifications Unless the system is pressurized the inlet to the deaerator section must be higher than or equal to the highest point in the system to prevent pockets of air from collecting in system piping The head required at the circulation pump suction inlet must also be taken into account to avoid the possibility of pump cavitation In systems operating close to maximum fluid temperature the tank must be elevated enough possibly well above the highest point in the system to prevent pump cavitation by increasing the static head An inert pressurizing blanket may be considered as an alternative See Pressurized Systems Supports for tank mounting should be provided by the client contractor These should be suited for supporting the tank by the side rails The eyelets fitted to the tank are for lifting only Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 26 Vent for Piping to Safe Ca
109. he Heater Heater Procedure for First Shutdown Required Pressure Drop Across the Heater Burner Cycles Linkageless Modulation Nexus Display Siemens Linkageless Modulation On Off Burner Oil Fired Burner Dual Fuel Burner Operating Controls Daily Start Up Daily Shutdown Section 4 Maintenance 1 NOR OL Required Maintenance at First Shutdown General Maintenance Schedule Maintenance Procedures Safety Check Procedures Recommended Maintenance Schedule Troubleshooting Fulton Thermal Fluid Heater Log Sheet Section 5 Parts amp Warranty Section 6 Product Specs amp Data Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 3 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 4 ection 1 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 5 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 6 Section 1 Safety Warnings amp Precautions Prior to shipment the following tests are made to assure the customer the highest standards of manufacturing a Material inspections b Manufacturing process inspections c ASME welding inspection d ASME hydrostatic test inspection e Electrical components inspection Z Operating test g Final engineering inspection h Crating inspection Rigging your heater into position should be handled by a competent rigger experienced
110. he basic operation and function of controls 8 Cold Circulation Turn on the main power switches Check for proper fluid level in the expansion section of tank A centrifugal pump cannot be operated with the discharge valve closed without heating up dangerously The pump should be started with the suction valve full open and the discharge valve open a slight amount Check pump rotation Operating the pump in reverse rotation may cause extensive damage Turn the three position switch located on the front of the panel box door to Pump Jog the green pump motor starting button and observe the direction of rotation Rotation should be in the direction of the arrow shown on pump casing If the rotation direction is incorrect turn the three position switch back to Off immediately Change the wiring connections and recheck Check for proper alignment Realign at temperature Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 60 With the control switch set to Pump push and hold the pump start button check all manual resets on pressuretrols The circulating pump will run but the burner will not fire If the pump stops when the button is released check for proper flow in the system and review settings of high and low fluid pressure switches and differential pressure switch Check liquid level switch Check that all pressure gauge readings remain stable Pressure exceeding 100 PSIG or
111. he minimum differential pressure for that particular heater model number If the minimum required pressure is not known compare model of heater to chart on page 1 x of this manual a The call for heat circuit is the circuit that enables burner operation Fulton Thermal Corporation has used a variety of Temperature Controllers to act as the Call for Heat b Generally these controls work in combination with a control relay When the Temperature Controller calls for heat a signal is sent to the coil of a control relay that closes a normally open set of contacts in series with the burner circuit Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 115 c When the call for heat is met the signal is removed and the contacts return to their open state Situations that may interfere with the Call for Heat circuit include the following 1 Programming problem a Fulton has a general program for each of the temperature controllers we have used over the years Compare your current temperature controller program to Fulton s general program See the back of this section for general programming sheets for standard Fulton heaters Make changes as necessary Contact Fulton service department with any questions 2 Temperature controller failure a If the temperature controller is calling for heat but is not putting power on the output to the control relay the relay will not close the normally
112. he system Boilout can take anywhere from two to three days to complete Pressure testing on the system should be done by means of an inert gas such as nitrogen or by an air compressor producing dry air air with a dewpoint of 50 F or less Never perform a hydrostatic test on the system 23 Insulation a After the appropriate system tests have been satisfactorily completed all hot pipework including manifolds on the heater must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury Caution For reasons of safety the hot exhaust gas duct and chimney must be insulated or shielded within the locality of the heater The deaerator section of the combination tank must be insulated The expansion section of the combination tank must not be insulated nor should the thermal buffer section On units operated with inert gas blankets above the fluid in the expansion tank the entire combination tank including the expansion and thermal buffer sections may be insulated but is not necessary Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 47 It is recommended that for inspection and maintenance pumps flanges valves and fittings be left un insulated but suitably shielded for safety Hot oil pipe insulation should be a minimum of 2 thick high temperature laminated foamglass cellular glass insulation as manufa
113. hermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 118 j The switch setting is improper 1 The adjustment screw for the air switch is located opposite the electrical connections A gray cap covers the screw Turn the screw clockwise to increase setting counterclockwise to decrease setting The switch setting should be set in such a way that with 50 of the air box opening blocked the switch will trip Reset switch setting reset the flame programmer and try to light the unit again k Auxiliary Blower Motor Starter 1 All C model heaters use an auxiliary set of contacts on their blower motor starter to prove that the burner motor is latched on This is a normally open set of contacts mounted on or built in to the blower motor starter The Auxiliary Blower Motor Contacts are a safety device that proves that the blower motor starter is latched in These contacts work in redundancy to the air switch to prove that there is proper makeup air There is no manual reset on the auxiliary contacts themselves to indicate a trip If the contacts do not make it is generally one of the following issues The blower motor starter coil is bad 1 If this is the case the blower starter will not latch in Check for voltage to the coil If proper voltage is present and the starter does not pull in that proves the coil is bad Replace the starter reset the flame programmer and try to light unit again m The
114. ically 3 1 or 5 1 modulation is provided In this case minimum load is one third of full firing rate 4 The modulating temperature controller is set to maintain the desired fluid outlet temperature Due to the temperature rise across the heater this may be considerably higher than the inlet temperature 5 Ifthe unit is equipped with a modulating controller it will be located on the face of the electrical cabinet The temperature setpoint in the controller can be adjusted following the instructions in the component data sheet section of this manual n Additional Modulating Controls 1 The modulating motor is controlled by a temperature controller located in the control panel Its function is to drive modulating fuel valves and air damper to their correct position as dictated by the flame programmer during pre purge and post purge and to correctly position both during the normal firing cycle as required by the proportioning temperature controller A modulating valve is positioned in the main fuel line to control the fuel input according to demand by the modulating motor o Pressure Gauges 1 All units have two pressure gauges measuring the thermal fluid pressure at the inlet of the heater and at the outlet of the heater The difference between the readings of the two gauges indicates the pressure loss across the heater The difference must not fall below the recommended value Recommendations are based on heater size and are listed in Secti
115. identical readings at inlet and outlet gauges indicate a closed valve If an extremely high vacuum i e 15 Hg or more is indicated on the compound gauge the valve between the circulating pump and the combination tank may have been left closed In this case little or no pressure will be indicated by other gauges 9 Filtering the System a Initially readings on the compound gauge will indicate zero or slightly positive pressure During the first few moments of flow this reading will go towards vacuum indicating that the strainer is becoming plugged Typically a reading of 3 Hg or greater vacuum on the pump suction gauge indicates that the strainer must be cleaned The strainer screen should be back flushed or pulled cleaned and replaced Strainers should be cleaned by means of compressed air A rag will merely force the smaller particles into the mesh of the strainer It is recommended to place a lint free rag in the center of the strainer and blow air from the outside trapping the debris in the rag Allow the pump to run again for several minutes and repeat the filtering process until pump suction pressure remains steady after cleaning The amount of time which must be allotted for filtering varies with the system When the system is initially brought up to temperature additional pipe scale and welding slag will loosen and enter the fluid stream This will be trapped in the strainer causing vacuum at the pump suction This pr
116. ies Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 169 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 170 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 171 No part of this Installation Operation and Maintenance manual may be reproduced in any form or by any means without permission in writing from the Fulton Companies Fulton Boiler Works Inc Fulton Heating Solutions Inc amp Fulton Thermal Corporation are part of the Fulton Group of Companies a global manufacturer of steam hot water and thermal fluid heat transfer systems Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 172
117. ific details of individual systems b Liquid Level Switch When Combination Tank is Supplied 1 Inthe event of system fluid loss the level in the expansion section of the combination tank will drop and the liquid level switch will shut the unit down Control power will be lost to the panel 2 To confirm operation manually trip the liquid level switch Unit should shut down pump will stop Combination Deaerator Expansion Tank c Air Safety Switch 1 This switch requires that the blower fan deliver combustion air before energizing any fuel valves 2 While firing disconnect the copper line from the fitting in the top cover of the air switch The burner should shut down Attempt to restart the unit by resetting the flame programmer 3 Blower motor will start but firing sequence should not begin d Blower Motor Starter For units equipped with manual trip test button or motor starter 1 While firing actuate the manual trip button on blower motor starter Unit should lock out Attempt re start by resetting the flame programmer Purge cycle will not begin Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 82 2 Reset motor starter blower should start and purge cycle will begin e Differential Pressure Switch 1 The heater is dependent on proper flow for operation therefore a differential pressure switch is used to sense the pressure drop across the heater The differential pressure
118. include a flex connector and a valve 15 Piping a b All pipework should be constructed from seamless mild steel pipe conforming to ASME SA 106B or SA 53B Schedule 40 or equal Expansion joints or properly designed and sited loops should be provided to accommodate thermal expansion Thermal expansion should be calculated using the maximum possible utilization fluid temperature regardless of whether the pipe considered is in the feed or return circuit Steel pipe will expand approximately 1 per 100 over a 100 F temperature rise 1 mm per meter over 100 C rise Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 39 Supports and anchors must be provided for all pipes where necessary to prevent undue stresses from being placed on items of equipment including pumps valves and the heater Supports and anchors which will not interfere with thermal expansion should be chosen All pipe joints should be of either welded or flanged construction Screwed joints must be avoided where possible In no instance should screwed joints be used in the flow circuit All flanges should be welded to the pipe and not screwed Flanges should be 150 or 300 raised face flanges SA105 Gasketing material suitable for use with thermal fluids at high temperatures should be used to make all flanged joints Flexible graphite gaskets are suited for most thermal fluids Recommended gasket thickness is 1 10 1 8 inch
119. ings and valve packings Repair leaks and tighten valve packings to the point of stopping leak f Upon putting unit back in operation check all gauge readings and compare to values given to you by the start up technician Note any discrepancies and contact manufacturer 2 General Maintenance Schedule Daily a Complete the log sheet attached at the end of this section at least once per day as a minimum It is recommended that the log sheet be filled out twice per shift of operation The log sheet is available from the Fulton Service Department or www fulton com b Make visual inspection of the entire system for leaks Make repairs as soon as possible c Note any failures on the flame programmer noting fault number fault code fault annunciation fault hour fault cycle and fault time Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 93 d Check the exhaust for the presence of smoke If smoke is present contact Fulton Service Department at 315 298 7148 or contact your local Fulton Thermal Representative e In systems utilizing linkage check all linkage components for tightness f In systems utilizing a water cooled thermal fluid circulating pump check level of lubricating oil in self leveling reservoir and check cooling water circulation loop for proper operation Weekly a Check inlet gas pressure at the beginning of the gas train This should be accomplished by the installation o
120. ion 2009 0929 Page 50 4 During the first few months of operation sampling may be carried out at frequent intervals to confirm that system performance has been predicted correctly If the supplier of your thermal fluid does not contact you within four weeks of commissioning contact the supplier and make certain that the fill is registered for routine analysis LOW INLET PRESS SW HIGH INLET PRESS SW i j Thermal Fluid Breakdown 1 The possibilities of thermal fluid breakdown are very slim ina typical closed loop thermal fluid system Fulton s D A tank creates a cold seal of fluid that is slightly above ambient temperature This prevents oxidation that will happen when high temperature fluid contacts air This will also occur when hot thermal fluid contacts air at a leak in the system piping Oxidized thermal fluid becomes acidic and will damage the thermal fluid system Thermal fluid breakdown can occur in sections of piping where there is a low flow Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 51 condition A low flow rate through the heater will result in high film temperatures leading to breakdown of the thermal fluid 3 Multiple pressure switches and a differential pressure switch are used to prevent this condition from occurring These safeties must not be bypassed at any time 4 Exceeding the maximum operating temperature of the thermal fluid will al
121. is plugged crimped or pointing in the wrong area 1 If the sensing line to the air switch is crimped or blocked the switch will not sense the proper pressure Ensure that the sensing line is clear and not crimped by removing both sides of the sensing line and using compressed air to blow through the line Also ensure that the elbow acting as an air scoop is pointing directly into the air stream Reset the flame programmer and try to light the unit again e The switch setting is improper 1 The adjustment screw for the air switch is located opposite the electrical connections A gray cap covers the screw Turn the Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 117 f Air Filter Switch 1 screw clockwise to increase setting counter clockwise to decrease setting To set switch run unit at low fire Increase setting 1 2 turn every 5 seconds until unit trips on interlock Decrease setting by 2 full turns Reset unit C model heaters with an air filter box or ducted supply air have an Air Filter Switch This is a normally closed switch that opens on too high of a suction pressure at the burner fan inlet This switch is generally a diaphragm type switch The Air Filter Switch is a safety device that proves that there is not too negative of a pressure at the combustion blower inlet This switch is only used on units that have a built in air box for use as a duct connection or air filtering d
122. ives the air damper to its low fire position All start interlocks must be proven or the flame programmer will lockout 4 Units with Gas Pilot Ignition and pilot are energized and a timed trial for pilot ignition begins After the pilot flame is proven the main fuel valve is energized Ignition and pilot fuel are turned off and the modulating motor is released to automatic 5 Units with Spark Ignition The spark and oil valves are energized and a timed trial for ignition begins With the flame proven the control advances through its main light off sequence and the ignition shuts off At this time with the flame proven the modulating motor is released to automatic 6 When the modulating motor is released to automatic it receives its signal from the modulating temperature controller The modulating motor then drives the modulating fuel valve and air damper in proportion to the heat demand 7 During the initial call for heat the modulating fuel valve and air damper will drive to their full fire position As the temperature set point is approached the modulating motor will continue to reduce the input until low fire position is reached Input automatically increases and decreases according to load demand 8 When the fluid temperature reaches the set point of the on off temperature controller or of the optional operating limit controller all fuel valves will close and the flame programmer will advance to the purge cycle When the post
123. k inlet and the highest point in the system Divide that number by 2 31 this will indicate the nitrogen pressure the system should be set for Adjustment can be made via the regulator mounted on top of the D A tank Note Tanks are non code as a standard Non code tanks cannot be pressurized over 15psig Tanks built to ASME code Section VIII Div 1 are available upon request Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 57 5 Circulating Pump a Read manufacturer s instruction manual thoroughly If the pump is supplied by Fulton Thermal Corporation manufacturer s literature is included in this manual Note Do not run the pump before filling it with fluid b The pump should never be run without fluid in the casing For pumps equipped with mechanical or air cooled seals air must be bled out of the stuffing box area to ensure that thermal fluid has lubricated all seal and bearing areas Operation of the pump even a short time without bleeding first will damage the pump c Also use the thermal fluid as a barrier fluid Remove the 3 8 plug at the barrier fluid fill port Fill the cavity with thermal fluid until it comes out of the overflow tube Replace the 3 8 plug d Mechanical Air Cooled Seal 1 Open the air bleed connection located directly over the pump shaft Replace plug when a steady stream of thermal fluid free of entrained air flows f
124. l as construction debris can foul the oil and cause the need for the filters to be Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 42 cleaned more than need be This can range from simply using a rag to ordering pickled pipe Pickling is a process where the piping is first soaked in an acid bath then soaked in a neutralizing bath then given a protective oil coating d All pipes should be installed with a pitch to facilitate draining and venting Standard gaskets supplied by Fulton for operating temperatures above 650 F are Flexitallic Spiral Wound Recommended Loads for Flexitallic Spiral Wound Class 150 Gaskets SAE Grade 5 Bolts typical or Equal Nominal Flange Size Diameter of Bolts Preferred Torque Required per Bolt Inches Number of Bolts Inches Ft Lbs 1 2 4 1 2 45 3 4 4 1 2 45 1 4 1 2 45 1 4 1 2 45 1 4 1 2 45 2 4 5 8 90 2 V2 4 5 8 90 3 4 5 8 90 3 Ve 8 5 8 90 4 8 5 8 90 5 8 3 4 150 6 8 3 4 150 8 8 3 4 150 10 12 7 8 240 Recommended Loads for Flexitallic Spiral Wound Class 300 Gaskets SAE Grade 5 Bolts typical or Equal Nominal Flange Size Diameter of Bolts Preferred Torque Required per Bolt Inches Number of Bolts Inches Ft Lbs 1 2 4 1 2 45 3 4 4 5 8 90 1 4 5 8 90 1 4 5 8 90 1 4 3 4 150 2 8 5 8 90 2 Ve 8 3 4 150 3 8 3 4 150
125. l see the following Setpoint Fault Number If Control is in Fault Hours Run Flame Signal range is 0 100 with a minimum signal of 10 and of modulation In the event of a Fault on the Nexus you will need to Press Fault Mute Mode key to reset the control Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 69 c Site Pass Code and Parameters Default Value is 154 1 d Engineers Key 1 The site pass code allows the Adjustment of some parameters the default code is 154 and it is adjustable You will be able to view all the options even though you cannot change them The options that you can change are the following a 6 3 Setpoint 1 Control Value 6 4 Setpoint 1 Proportional Band 6 5 Setpoint 1 Integral Term 6 6 Setpoint 1 Derivative Term 7 1 Setpoint 1 Low Limit Value 7 2 Setpoint 1 High Limit Value g 7 5 Setpoint 1 Warming Limit 298 h 7 6 Setpoint 1 Warming Time The same for Setpoint 2 if enabled To change the setpoint you Press Com Enter key enter the Site Pass Code using the Up Down keys then Press Com Enter key Use the Up Down keys to advance through the options Note Pressing the Button too hard can cause you to skip over an option Advance through the options until you reach 6 3 Use the Left Right Arrows to select the parameters then use the Up Down keys to make the changes required When a change is made Press Com Enter key Use the Left Right arrow to l
126. let Pressure Switch a Note the original setting of the switch and turn adjustment screw counterclockwise while observing heater outlet pressure gauge until switch trips The pointer on the switch should be within 2 psi of the observed pressure Reset switch to the original set point Outlet Inlet High Outlet Pressure Switch Air Switch a Remove the copper tubing from the bottom of the air switch with the fan running Air switch should trip the interlock circuit Re attach copper tubing and reset flame programmer Air Filter Box Switch a With heater running at high fire block opening to air filter box by 50 Slowly close off further until switch trips Air switch should trip at just over 50 blockage Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 101 Air Switch Air Filter Switch Temperature Limit s a Adjust set point s of temperature limit s down to a point lower than the PV process variable is typically the current fluid temperature at the heater outlet Solid state controls will deactivate a control relay powering a set of n c contacts in the interlock circuit Analog controls will open their contacts in the interlock circuit Trip temperature should be within 5 degrees of PV temperature Reset temperature limit if reset exists and reset flame programmer High Low Gas Pressure Switch a Shut off the main gas valve prior to the gas train and attempt to light
127. let manifold The temperature setpoint in the controller can be adjusted following instructions in the component data sheet section of this manual Typically one controller is provided to sense the temperature on the heater outlet This controls the operation of the heater by switching it on and off An adjustable two point differential between shut off and start up is built into the controller This prevents frequent cycling of the burner The controller is set to provide the desired outlet fluid temperature Due to the temperature rise through the unit this may be considerably higher than the inlet temperature If the unit is equipped with an on off controller it will be located on the face of the electrical cabinet The temperature setpoint in the controller can be adjusted following the instructions in the component data sheets section of this manual m Modulating Controls 1 2 All coil models are standardly equipped with modulating controls The modulating temperature controller continuously regulates the outlet fluid temperature between the minimum firing rate and high fire When the unit is on low fire and the temperature Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 87 continues to climb past the setpoint the heater will shut down It will typically re start when the process temperature drops 7 F below setpoint 3 Minimum load depends on the degree of modulation provided Typ
128. lot Oil fired units may be 2 stage in which the 1 stage to light would be considered the pilot or may have a gas pilot In either case during the pilot proving period the flame programmer must sense a strong enough flame to initiate the opening of the main valves Pilot flame strength is inadequate 1 Cycle the unit During the pilot trial for ignition carefully observe the pilot flame strength 2 On Honeywell controllers the pilot flame strength must be between 1 25 to 5 0 VDC On Fireye controllers the pilot flame strength must be greater than 10 VDC 3 Current controls are supplied with a test switch that can hold the programmer in the pilot trial for ignition stage If a pilot signal greater that 0 0 but less than the minimum required is detected look through the sight hole provided on the burner plate of the heater to visibly detect flame If flame is seen make small adjustments to increase pilot gas and air to provide larger flame Pilot sensing device does not work properly 1 Cycle the unit If a pilot signal of 0 0 is detected look through the sight hole provided on the burner plate of the heater to visibly detect flame 2 If flame is seen your flame detection device or amplifier may be faulty If the unit has a flame rod lockout and tag heater s electrical circuit and fuel supply Pull pilot assembly out of unit Inspect the flame rod If the flame rod is corroded shows isgns of heat impingement has been burdned of
129. luid at operating temperature and pump running until the pump shuts down Note the setpoint and lower by 10 PSI then re start pump The setpoint at cutout should correspond to the reading on the output pressure gauge With the unit cold and pump running lower the high fluid pressure cutout switch until the pump shuts down Note the setpoint and raise by 10 PSI then re start pump The setpoint at cutout should correspond to the inlet gauge reading Low INLET High Low Fluid Pressure Switch Lit INLET HIGH OUTLET PRESS Sw A h Gas Pressure Switch Gas Fired Units Only 1 2 3 4 While firing shut main gas cock Unit will lock out Attempt restart by resetting flame programmer Unit will start purge and lock out Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 84 5 Open main gas valve and reset flame programmer 6 Reset high side of switch unit will start purge and fire High Low Gas Pressure Switch i Operating Temperature Controls 1 The Coil Design unit is a fired heat exchanger and the safe control and monitoring of the thermal fluid temperature is of vital importance The safe maximum temperature of the fluid must be strictly adhered to When consulting fluid manufacturer s literature for the safe maximum fluid temperature note that the temperatures quoted are the actual limit to which any of the fluids may be subjected It is important to remember that
130. mer to allow clear access to the top of the heater for maintenance purposes Fulton Thermal Corporation will advise on the suitability of the access provided and will be glad to give any assistance that may be required in this respect Access provision should avoid possible contact with hot pipework flues etc Failure to provide suitable and safe access at the time of commissioning may cause delays as our Service Engineers are instructed not to commence commissioning if hazardous conditions exist Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 19 Minimum Clearance for Coil Removal Model Inches Meters FT 0080C 60 1 6 FT 0120C 66 1 7 FT 0160C 66 1 7 FT 0240C 73 1 9 FT 0320C 80 2 0 FT 0400C 94 2 4 FT O600C 124 3 2 FT O800C 126 3 2 FT 1000C 126 3 2 FT 1200C 126 3 2 FT 1400C 140 3 6 FT 0400S 124 3 2 FT 0600S 124 3 2 FT 0800S 126 3 2 7 Circulating Pump a Installing the pump in accordance with the manufacturer s specifications and these instructions will prolong the life of the pump and contribute significantly to the successful operation of your Fulton heater system The pump manufacturer s installation and operation instructions can be found in Section 5 of this manual From Outlet of Deaerator Pipe Must Be Diameter of t Pump Intake First Fitting Pipe Support Must Be Provided Not To Be Welded On Both End
131. mized fuel oil An electric spark between two electrodes provides ignition of the atomized mixture except where code requires a gas pilot This spark is produced by a high voltage transformer Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 80 The flame programmer circuit controls normal operation of the burner The sequence includes purging of the combustion area for a set period ignition and opening of magnetic valves on the oil circuit post purge of combustion area and return to re start position An ultra violet scanner mounted on the burner casing and facing the light of the flame monitors the flame Safety lock out occurs within a preset minimum time in the event of insufficient unstable or non existent flame After fault has been corrected reset programmer by depressing the red push button on the casing of the burner control box Proper fuel pressure at the burner nozzle is essential The correct firing rate is obtained by setting the fuel oil pump to give the design pressure for each unit This is done at the factory Pressure is measured by connecting a 0 400 PSI 0 25 bar test pressure gauge to the gauge connection on the fuel pump The fuel pressure gauge indicates the pressure of the fuel at the burner nozzle Typical pressures range between 160 350 PSI 12 22 bar Note the correct setting upon commissioning Modulating units should have a second pressure gauge monitoring the pressure in the
132. mxf brass ball valve Stock 2 30 000021 1 lube cock 4 86 2 21 Stock 2 30 000022 1 1 4 lube cock 6 5 2 95 Stock 2 30 000013 1 1 2 lube cock 7 0 3 18 Stock 2 30 000012 2 lube cock 10 0 4 55 Stock 2 30 000005 3 lube cock 2 7 1 23 Stock 2 30 000111 v ball valve 25 11 Stock 2 30 000113 1 gas cock 2 0 91 Stock 2 30 000114 1 1 4 gas cock 3 0 1 36 Stock 2 30 000115 1 1 2 gas cock 4 8 2 18 Stock 2 30 000116 2 gas cock 08 36 Stock Gas Pressure Regulators 2 30 000102 Maxitrol RV48 1 pilot 7 32 Stock 2 30 000104 Maxitrol RV58 CU 15 amp Stock 2 30 000515 Maxitrol RV81 1 1 4 4 68 2 13 Stock 2 30 000516 Maxitrol RV81 1 1 2 5 94 2 7 Stock 2 30 000517 Maxitrol RV91 2 8 28 3 76 Stock 2 30 000518 Maxitrol RV1113 S o 1688 767 Stok 2 30 000677 Maxitrol 325 3 2 10 psi pilot 8 36 Stock 2 30 000678 Maxitrol210D 1 1 4 10psi 5 6 2 55 Stock 2 30 000686 Maxitrol 1 1 2 10psi 5 94 2 7 Stock 2 30 000679 Maxitrol 2 10psi 10 0 4 55 Stock 2 30 000680 Maxitrol3 10psi o z4 1065 Stok 14 WC max incoming gas pressure Consult factory for spring ranges Safety Shut off Valves Actuators 2 30 000298 V2 8215G20 Pilot Valve 1 64 75 Stock 2 40 000214 Fluid power actuator V4055V 1031 13 7 6 23 Stock 2 40 000220 Fluid power actuator w indicator V4055D1043 12 8 5 82 Stock 2 30 000295 Fluid power actuator N
133. n equipment and other equipment should be considered Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 17 4 Approximate Floor Loadings a Free standing figures take the weight of the heater alone into consideration Floor loadings for skid mounted units vary with configuration Model Heater Only FT 0080C 500 Ibs ft2 FT 0120C 400 Ibs ft2 FT 0160C 450 Ibs ft2 FT 0240C 450 Ibs ft2 FT 0320C 450 Ibs ft2 FT 0400C 450 Ibs ft2 FT 0600C 550 Ibs ft2 FT 0800C 500 Ibs ft2 FT 1000C 500 Ibs ft2 FT 1200C 400 Ibs ft2 FT 1400C 450 Ibs ft2 FT 0400S 675 lbs ft2 FT 0600S 675 lbs ft2 FT 0800S 525 lbs ft2 5 Minimum Make Up Air Required and Recommended Area of Opening for Vents Model Minimum Make Opening Area Opening Area Up Air SCFM in Lower Vent in Upper Vent FT 0080C 200 400 135 FT 0120C 300 600 205 FT 0160C 400 800 270 FT 0240C 600 1200 400 FT 0320C 800 1600 535 FT 0400C 1000 2000 670 FT 0600C 1500 3000 1000 FT 0800C 2000 4000 1335 FT 1000C 2500 5000 1670 FT 1200C 3000 6000 2000 FT 1400C 3500 7000 2335 FT 0400S 1000 2000 670 FT 0600S 1500 3000 1000 FT 0800S 2500 4000 1335 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 18 6 Access a b Access around the heater should be provided to facilitate maintenance Appropriate clearances for all sides
134. n fluid and system volume c Deaerator Section 1 At start up the primary purpose of the deaerator section is to remove all volatiles from the system to avoid pump cavitation The deaerator section also allows oxygen to be vented from the system on a continuous basis during operation to avoid oxidation of the thermal fluid and removes other volatile particles generated by the fluid itself during system operation This section of the tank must be insulated d Thermal Buffer Section 1 A system of interconnecting pipe work in the thermal buffer tank section prevents the movement of any oil that has not cooled sufficiently into the expansion section This avoids contact of very high thermal fluid temperature with oxygen contained in the Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 25 atmosphere which causes fluid breakdown DO NOT insulate this section e Sizing The Tank For The System f Sizing Example 1 g Location 1 Expansion tank capacity is the total volume of the tank It is necessary to have some air space available at the top of the tank to avoid spillage or overflow At initial fill for system volume calculations the deaerator and cold seal sections must be filled completely and the expansion section must be filled to a level of 4 inches to make the liquid level switch The volume between the initial fill level and the safe full level is the amount available for expansion T
135. n length c The pipe used should be the same size as the inlet of the pump The piping in the immediate vicinity of the pump must not be supported by the pump The pump is not designed to bear the weight of the piping and weight on any part of the pump will throw it out of alignment Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 21 Typical Fulton Thermal Piping Schematic Vent Piping should be full size of expansion tank vent Manual Low Level Test Line d Typical Fulton Thermal Piping Schematic Thermal Fluid Heater Thermal Fluid Circulating Pump Safety Relief Valve Thermometer Pressure Gauge Thermal Fluid Heated Equipment Bypass Valve to maintain full flow to heater Expansion Joints as required Anchor and Pipe Guides as required Expansion Tank Deaerator Tank Deaerator Tank inlet must be highest point of piping Thermal Buffer Tank Catch Tank for drain of pressure relief valve cold seal expansion tank and vent Locate in safe area Gate Valve Strainer 3 4 System Fill Connection Flexible Connection as necessary Isolating Valve as necessary Manual High Level Test Line Buffer Drain Note The catch tank should be appropriately sized based on the system volume and configuration Under normal operating conditions the catch tank should be empty Fluid that is expelled into the tank should not be reintroduced into the system
136. n switch should be 10 under pressure read Call Fulton if you have any questions Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 122 bb Gas regulator has failed closed 1 Regulators will usually fail safe in the closed position The gas regulator can be checked by checking upstream pressure and comparing to downstream pressure Make sure that the upstream pressure is not above the rating of the regulator If regulator has failed replace reset input and adjust input throughout the range cc Low oil pressure switch 1 All oil fired modulating thermal fluid heaters have a Low Oil Pressure Switch This is a normally closed diaphragm switch that opens on a pressure decrease below set point The Low Oil Pressure Switch is a safety device that protects the burner from receiving too low of an oil pressure The switch senses this pressure just downstream of the gas pump If this switch trips it is generally one of the following issues dd Oil pressure setting on the back pressure valve is too low 1 At low fire the modulating oil valve is at its most open position resulting in the least amount of back pressure in the fuel train With unit running at low fire check oil pressure and compare to factory test fire sheet Make sure oil pressure reading is within 10 psi of factory reading If there is a difference adjust back pressure regulator Adjust for proper combustion throughout rang
137. n toxic in the case of leakage d Sufficient lubricity i e not likely to cause seizure The thermal fluid manufacturer must guarantee the characteristics of the product and verify that the fluid bulk temperature limitation exceeds the expected operating temperature After a fluid is selected refer to the manufacturer s recommendations published in compliance with OSHA If the fluid expansion volume from 50 F to 600 F exceeds 20 of the initial fluid volume consult Fulton Thermal Corporation Note Fulton Thermal Corporation cannot be held responsible in the case of accident or damage resulting from the use of inadequate fluid i Routine Analysis of Heat Transfer Fluid 1 Nearly all leading manufacturers of heat transfer fluids provide an after sales service to monitor the condition of the fluid in operation and make recommendations when replacement becomes necessary Each fluid manufacturer has procedures for regular testing and analysis of the fluid These usually allow for a sample to be taken and analyzed at least once a year although actual frequency will depend on operating temperature number of hours operated weekly and the results of tests made during the first weeks of system operation Fulton Thermal Corporation recommends that the thermal fluid in your system be analyzed within the first two months after start up Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Vers
138. nd clean the coil Fulton Thermal Corporation should be consulted in this matter c Improper switch setting 1 The High Inlet Pressure Switch should be set at ambient temperature The setting should be 5 psi over than the maximum pressure read on the heater outlet pressure gauge during proper operation d Differential Pressure Switch 1 Units newer than mid 1993 have a Differential Pressure Switch This is a normally open diaphragm switch that closes with a proper heater differential pressure between the heater inlet and outlet Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 113 2 The purpose of the Differential Pressure Switch is to protect the heater coil from too high of a temperature and to protect the thermal fluid from exceeding its maximum film temperature Each heater model number has a specific minimum differential pressure See Section 1 if you do not know this pressure This pressure is the difference in pressure between the heater inlet pressure gauge and the heater outlet pressure gauge Differential Pressure Switch Break a An obstruction downstream of the heater outlet 1 Any obstruction downstream of the flow switch es will increase the pressure that the heater outlet sees Any increase in outlet pressure will result in diminished flow This obstruction will generally result from an improper valve setting Observe heater outlet pressure at temperature wi
139. nspect the flame rod If the flame rod is corroded shows signs of heat impingement has been burned off or has cracks in the porcelain replace with a new flame rod Reinstall and cycle unit If the unit has a U V scanner lockout and tag heater s fuel supply Remove U V scanner from U V sight tube Make sure that the lens of the scanner is clean Use a lighter or match and make a flame in front of the scanner eye Lens should flicker If unit does not flicker change U V scanner If this change does not work change U V amplifier Reinstall and cycle unit f Room air pressure is different from outside air pressure 1 Check room air pressure relative to outside air pressure Heater room pressure should equal outside air pressure Significant differences in pressure will result in an erratic flame which will not deliver a strong flame signal g Unit is experiencing too great of a restriction 1 At the breaching of the heater take a draft reading Draft should read between 02 w c and 04 w c with the heater off and between 04 w c and 08 w c with the unit on A restrictive draft would be a draft that was positive A restrictive draft is usually the result a stack that is undersized a stack with too many elbows or a stack whose cap or piping is warped and damaged Another source of restriction results from broken refractory If the unit s refractory breaks large enough pieces could block the flue passes The
140. o a minimum The minimum required gas pressure at the stop valve varies with the model of heater The requirements for natural gas fired coil design models are as follows a Models FT 0080 C to FT 0400 C and FT 0400 S 14 w c b Models FT 0600 C to FT 0800 C and FT 0600 S to FT 0800 S 40 w c c Models FT 1000 C to FT 1400 C 120 w c Note Low emissions burners for all models require 10 psi Even when the unit is shut down the gas supply pressure must never exceed these values When operating the supply pressure should not drop below these limits a Not less than 11 w c where 14 w c is required b Not less than 30 w c where 40 w c is required c Not less than 100 w c where 120 w c is required The supply pressure must be regulated by a non stacking tight shut off regulator Diaphragms gas valves pressure regulators and pressure switches on all gas fired units have vent connections which must be vented per local code On gas fired units with NFPA 85 valve trains there is a vent valve which must be piped to atmosphere Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 32 Oil Connections 9 Fuel pipes should be of approved materials and of a diameter suitable for the quantity of oil being delivered to the burner and the static head available The fuel connection should be made in accordance with the details on the enclosed fuel pump cut sheet
141. ocedure must be followed as necessary in the course of heater operation Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 61 Illustration indicates proper fluid level in the expansion section of the deaerator tank Vent for Piping Expansion to Safe Catchment Volume Expansion Tank Liquid Fluid In Thermal Level Buffer Switch Section Deaerator Section BB Hot Fluid E Medium Fluid E Cool Fluid E Gases Steam Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 62 10 Firing the Heater Heater ty NE a Y Pressure Gauges During a system boil out it is imperative that all system legs or paths are open to flow to ensure no water is trapped in the system Warning Never open a cool or unheated user leg of a system when the rest of the system is above 250 F Check for correct fuel feed All air must be eliminated from fuel lines gas piping preheaters etc All manual valves in the fuel oil supply line must be open Do not run the fuel pump dry or without fuel lines connected to fuel source Do not allow the fuel oil pump to pull a vacuum Check safeties Disable N2 blanket if equipped and open vent line on DA tank Set control switch to Heat The burner will begin the call for heat if oil temperature is below setpoint With burner firing and pump running keep checking the gauges indicating pump and circuit pressures Mak
142. oltage of 3 Heater Design a The heater shall be of a vertical helical coil self venting design and the pressure vessel coil construction shall be carbon steel ASME SA106B Schedule 40 or equal with a design pressure of 200 PSI standard at 700 F Heater will be per ASME Code Section stamped at 150 PSIG MWP trimmed at 100 PSI unless otherwise specified Test pressure will be per ASME Code Section Minimal refractory lining shall be supplied in heater combustion chamber to avoid thermal inertia and overheating of the thermal fluid should a pump or power failure occur IT shall be completely factory piped wired and tested Thermal efficiency shall be 85 or higher on fuel LHV The shell coil and burner are surrounded by the preheater jacket This jacket is steel welded construction with an integral floor plate bolted top cover to facilitate coil removal access panels for air chamber inspection and has an aluminum inner air baffle This preheater obviates the requirement for insulation of the Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 159 heater and simultaneously boosts thermal efficiency by preheating incoming combustion air The following instrumentation controls safety devices shall be supplied as a minimum requirement 1 10 11 12 13 14 15 16 17 4 Burner a High temperature safety switch interlock at heater outlet shutdown and alarm signal at terminal
143. omes apparent This warranty does not include freight handling or labor charges of any kind These warranties are contingent upon the proper sizing installation operation and maintenance of the boiler and peripheral components and equipment Warranties valid only if installed operated and maintained as outlined in the Fulton Installation and Operation Manual No Sales Manager or other representative of Fulton other than the Quality Manager or an officer of the company has warranty authority Fulton will not pay any charges unless they were pre approved in writing by the Fulton Quality Manager This warranty is exclusive and in lieu of all other warranties expressed or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose Fulton shall in no event be liable for any consequential or incidental damages arising in any way including but not limited to any loss of profits or business even if the Fulton Companies has been advised of the possibility of such damages Fulton s liability shall never exceed the amount paid for the original equipment found to be defective To activate the warranty for this product the appropriate commissioning sheets must be completed and returned to the Fulton Quality Assurance department for review and approval Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 155 Fulton Thermal Corp Vertical Coil Thermal Fluid
144. on Back the plug out slowly to the last two or three threads Allow any pressure under plug to bleed slowly to prevent a spray of hot oil Warning During a system boil out it is imperative that all system legs or paths are open to flow to ensure no water is trapped in the system Warning Never open a cool or unheated user leg of a system when the rest of the system is above 250 F Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 10 Note Do not open drain or vent valves during operation Note If excessive amounts of thermal fluid is vented from the system additional thermal fluid may be required in the system Note Flash steam may be generated at any point up to the operating temperature Watch for gauge fluctuations Note Start up technician should verify that all valves are opened prior to establishing flow and heat up Note If fluid or piping is added to the system the boil out procedure must be followed as water has to be introduced into the system If the burner loses flame while driving to a point then e Turn the main ON OFF switch to OFF Reset the loss of flame fault Press Escape on the AZL once Press Enter on the AZL to reset the control The red light on the panel box door should go out e Adjust the air and gas servos for that point while the burner is off Follow steps 28 29 e Turn the m
145. on 2009 0929 Page 99 Stack Limit a The limit manufacturer presets the stack limit Testing can be performed by removing switch from stack and applying heat over that of the switch set point for several seconds The switch can then be reset and re installed Manual Reset Differential Pressure Switch a With the circulating pump running observe the difference in pressure between the heater outlet gauge and the heater inlet gauge Remove the top cover of the differential pressure switch Note the original setting of the switch and turn adjustment knob clockwise until switch trips The pointer on the switch should be within 2 psi of the observed pressure difference Reset switch to the original set point t a we A aA ts ads aAa alb Aas oa yy rer bs Differential Pressure Switch Low Inlet Pressure Switch a Slowly close the valve on outlet of main circulating pump observing heater inlet pressure gauge Note the pressure at which the switch trips This pressure should be roughly the set point of the switch minus any differential that is set High Inlet Pressure Switch a Note the original setting of the switch and turn adjustment screw counterclockwise while observing heater inlet pressure gauge until switch trips The pointer on the switch should be within 2 psi of the observed pressure Reset switch to the original set point Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 100 High Out
146. on Two 2 The gauge indicating the pressure of the fluid at the inlet is labeled Inlet The Outlet gauge indicates the pressure at the outlet and in effect indicates the resistance of the external pipework circuit The pressure gauge indicating pressure at the inlet of the pump is labeled Suction p Flow Proving Device 1 The heater is dependent on proper flow for operation therefore three pressure switches and a differential pressure switch are Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 88 used to sense flow across the heater Any one of these switches will shut the unit down in the event of loss of flow 21 Daily Start Up a b Check positioning of all system valves to ensure flow is not dead headed Visually check relative position of minimum level float switch in the combination tank Turn on power supply switches Where applicable open water cooling valve and check that water flows correctly For water cooled pumps only Open fuel valves Set three position switch to Pump Push and hold manual pump start button monitoring pressure gauges on heater Push reset on high fluid pressure switch located on the side of the control panel Release pump start switch Pump should continue to run When ready to begin heating move three position switch from Pump to Heat After a short delay resulting from the purge period the burner will ignite Make
147. on must be made in a manner that will prevent penetration of water or foreign bodies into the tank This connection must always terminate in a safe well ventilated area and has to be free of obstruction open to atmosphere and arranged in such a manner that in the event of discharge from the system thermal fluid could drain into a catch tank without danger to personnel or property Note Non code tanks cannot be pressurized over 15 psig Warning High temperature thermal fluid steam and combustible vapors may be vented through this connection b The vent run should be the same size as the tank outlet It should run pitch down from the outlet of the tank to the catch tank Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 28 If nitrogen is used on the system the vent can be reduced and should be piped with a positive closing valve at the catch tank The connection between the tank outlet and the horizontal pump inlet run should be as close to a vertical drop as possible It should not contain an excessive number of bends of length of pipe These faults could encourage pump cavitation As noted the inlet to the deaerator must be higher than or equal to the highest point in the system or a pressurized system must be used The liquid level switch supplied and shipped with the unit must be installed and wired to the control panel by the customer The high and low l
148. ons Gallons Volume FT 100 L 35 9 25 100 FT 200 L 52 25 46 184 FT 1000 L 264 80 232 1000 FT 1500 L 397 90 380 1400 FT 2000 L 528 145 444 1700 FT 3000 L 793 215 717 2600 FT 5000 L 1310 300 1168 4600 Example A System contains 175 gallons including the heater but not the tank You select the FT 200 L so you add 25 gallons to 175 You must look up the expansion rate for the thermal fluid Assume it s 25 200 gal x 1 25 250 gal 250 200 50 gal expansion The FT 200 L has only 46 gal available for expansion so the correct selection is FT 500 L Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 165 Specifications Coil Design Thermal Fluid Heater Model FT C 0080 0120 0160 0240 0320 0400 0600 0800 1000 1200 1400 Heat Output 1000 BTU HR 800 1 200 1 600 2 400 3 200 4 000 6 000 8 000 10 000 12 000 14 000 1000 KCAL HR 200 300 400 600 800 1 000 1 500 2 000 2 500 3 000 3 500 Thermal Fluid Content GAL 10 21 19 31 68 76 132 171 290 383 460 LITERS 38 80 72 116 258 288 498 648 1 097 1 448 1 741 Recommended Flow Rate GPM 50 75 100 150 250 250 375 500 615 730 800 M3 HR 11 4 17 22 7 34 56 8 56 8 85 2 113 6 139 167 182 Typical Circulating Pump Motor HP 10 10 15 15 20 20 30 40 50 50 60 KW 7 5 7 5 11 2 11 2 14 9 14 9 22 5 29 5 37 3 37 3 45 Typical Burner Motor HP 1 5 3 3 3 5 5 7 5 15 15 20 20 KW 14 2 2 2 2 2 2 3 7 3 7 5 6 11 2 1
149. open contacts and the heater will remain disabled If this is the case some controllers have separate sets of contacts that may be utilized in replacement of the damaged contacts Some rewiring and or reprogramming will be needed Contact Fulton service department if necessary 3 Temperature sensor failure a Different temperature controllers use different types of temperature sensors These may be Type J thermocouples mercury bulbs RTDs or another type of sensor It is possible for these sensors to malfunction To verify proper sensor operation use an alternate source of temperature detection such as an infra red temperature sensor to sense temperature at the same point 4 Control relay may have failed a Many temperature controllers energize a relay with a call for heat that in turn closes a normally open set of contacts to energize the burner circuit If your temperature controller is sending an output signal to the control relay but the burner does is not initiated check resistance across coil of the relay An open reading indicates that the relay needs to be replaced If the coil shows resistance energize coil and check Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 116 Burner Interlock contacts With coil energized normally open contacts should close resulting in a reading of control voltage on both the common and normally open contact c If voltage exists on common b
150. osion may result causing property damage personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliances WHAT TO DO IF YOU SMELL GAS e Do nottry to light any appliance e Do not touch any electrical switch do not use any phone in your building e Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions e f you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier For Your Safety The following WARNINGS CAUTIONS and NOTES appear in various chapters of this manual They are repeated on these safety summary pages as an example and for emphasis e WARNINGS must be observed to prevent serious injury or death to personnel e CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness e NOTES must be observed for essential and effective operating procedures conditions and as a statement to be highlighted It is the responsibility and duty of all personnel involved in the operating and maintenance of this equipment to fully understand the WARNINGS CAUTIONS and NOTES by which hazards are to be eliminated or reduced Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment
151. osition and the pilot should light The burner control will stay at this pilot hold stage so you can inspect and adjust the pilot as needed a The pilot gas pressure should match the test fire sheet b The flame signal should be greater than 90 when viewed from the top menu of the Siemens AZL display Once the pilot is adjusted properly and you are ready to light the main burner press Escape to the main menu b Setting Main Burner Ignition 1 Under Params amp Display RatioControl ProgramStop change the Program Stop to 52 Interv2 This is the main burner ignition position Press enter and confirm that 52 Interv2 is acknowledged in the current field This change moves the control to the main burner ignition point in the burner sequence This will allow the main burner to ignite Should the burner not light the gas and air servo motors are not synchronized to produce a combustible mix a Turn the ON OFF switch on the panel box to OFF b To reset the alarm Press Escape on the AZL once Press Enter on the AZL to reset the control The red light should go out Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 74 c Tochange the setting return to the front menu by pressing Escape until you are to the main menu Then select Params amp Display RatioControl GasSettings SpecialPositions IgnitionPos adjust the gas servo position by using the arrow key to move down to
152. pecially filtered compressed air will introduce moisture into the system Dry air or Nitrogen is recommended Make sure that there are no obstructions left in the thermal fluid circuit from pressure leak testing such as blanking plates in flanged joints Check that pipework is free to expand naturally when hot Open all valves to user circuits including air bleed valves at high points and drains at low points in the piping system and the liquid level test connections in the expansion section of the combination tank 3 Filling the System a The viscosity of thermal fluid is generally very high 500 cS at ambient temperature Below 50 F 10 C some fluids become very thick Fluid should be in a pumpable liquid form prior to filling the system Filling must be carried out from the lowest point in the system in order to prevent air pockets from forming A drain and fill point generally a 3 4 threaded coupling is provided on the inlet to the pump suction on skid mounted units Typically a portable high velocity pump such as the type used for chemical transfer is appropriate for filling the system Where only one or two drums of fluid are required a handheld pump may be practical Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 55 Note Some plastics can be dissolved by thermal fluid Note Do not use system circulating pump for system filling Note
153. pray of hot oil 7 The pump should not be subjected to thermal or pressure shock The thermal fluid should therefore be allowed to flow into the casing slowly 8 Check field work and make sure that all connections have been made in the proper places Check electrical connections to the motor 9 Rotate the pump shaft by hand to be sure there is no binding or rubbing within the pump or driver Correct any problems immediately 10 Check to see that pump is properly aligned while cold 11 The pump is properly aligned before it leaves the factory Because the system expands in operation the pump must be realigned when the system is at operating temperature 12 The coupling alignment of the pump and driver must be carefully checked for angular and axial alignment Check pump manufacturers instructions for these specifications The use of a dial indicator to check the axial and angular alignment is recommended 13 Realign at operating temperature if necessary 14 Make sure that the pump is properly greased or oiled e Pumps with Packed Seals 1 Make sure that the gland is finger tight before filling the system 6 Initial Start Up a These instructions are for use when the unit is being started up for the first time or after prolonged shutdown They are to be used in conjunction with the specific procedure information in titled section Routine Operation Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version
154. purge cycle begins the modulating motor will be in the low fire position At the end of postpurge the burner motor stops and the entire system is ready for restart on demand 14 Fireye Linkageless Modulation a The Fireye Linkageless system takes the place of the Fireye E110 UT 350 Mod Motor Linkage rods and arms This control is a microprocessor based on Flame Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 68 Safeguard and parallels positioning combustion controller This control has 3 levels of password protection 1 The site Pass Code is used by the end customer to make changes to the setpoint and to the PID values of the system 2 The Adjust Ratio Code is used by a competent burner technician to make adjustments to the air and to the gas based on combustion analysis In this mode you can also change the setpoint and the PID values 3 The Commissioning Ratio Mode is used by the factory to setup the parameters that are used in the Nexus control In this mode you can modify all the parameter settings and set up the profiles for gas air control High Low gas pressure switch Modulating Gas Butterfly Valve Modulation Motor 15 Nexus Display a The top line of the Nexus display shows the oil temperature and mode Auto Man This line can not be changed It is possible to change the second line of the display by using the Left or Right Arrow key by pressing the key you wil
155. r will open the main gas valve The flame is monitored by a flame sensor In the event of insufficient unstable or non existent pilot or main flame the flame sensor will cause a safety lockout of the flame programmer Safety lockout can also be caused if the flame sensor is Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 66 improperly positioned or grounded After fault has been corrected reset by pressing the red push button on the casing of the burner control box Top of a Dual Fuel Gas Oil Modulation Motor Fired Burner Model FT 0600 C Unt ie a Typical Gas Train for Models FT 0080 C through FT 0240 C g Modulating Burner 1 The function of the flame programmer must be greatly extended in a modulated system Along with limit controls operating controls and interlock devices the programmer automatically controls the operation of the burner blower motor ignition main fuel valves and modulating motor Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 67 2 The sequence of operation begins with power on limit switch and fuel valves closed and modulating limit controller closed and calling for heat The flame programmer begins its cycle and the blower motor starts pre purge The modulating circuit closes driving the air dampers to maximum for pre purge 3 The air flow proving switch must be closed now After timed pre purge the modulating motor dr
156. rik Valve Repair Kit 2 1 Consult factory 2 30 001261 ES10 Actuator Rebuild Kit 2 A Consult factory 2 30 001260 ES20 Actuator Rebuild Kit 16 07 Consult factory 2 30 001276 1 Valve Actuator ES10 6 Consult factory SteamPac Components 2 40 000420 Fulton Pump Relay 120V 5 23 Stock 2 40 000422 Base for Fulton Pump Relay 8 pin 25 11 Stock 2 40 000403 IDIDO Relay 2 0 91 Stock 2 40 000202 Motor Starter R4243 30 Amp 52 24 Stock 2 40 000421 120V Water Level Relay Stock 2 40 000423 Base for 120V Water Level Relay 11 pin Stock 2 40 000229 Pressuretrol L404A1396 2 0 91 Stock 2 12 000004 Handhole Gasket 04 02 Stock 2 12 000007 5 8 x9 1 4 Gauge Glass 2 09 Stock 2 12 000019 5 8 Rubber Gasket 004 0 0 Stock 2 12 000020 5 8 Brass Gasket 002 0 0 Stock 2 30 000149 Ya Water Gauge Valve w ball checks 1 5 68 Stock 2 30 000047 Ve Tri cock 42 19 Stock 2 20 000017 Low Water Cutoff Probe 17 1 8 cut to any length 23 Stock 2 20 000010 Low Water Probe 23 Stock 2 20 000012 High Water Probe 23 Stock Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 153 2 30 000029 v Float Valve 72 33 Stock 2 30 000028 Float Valve 76 35 Stock 2 30 000124 4 2 Float Ball only 6 27 Stock 2 12 000534 v Float Valve Disc 01 0 Stock 2 12 000535 3 Float Valve Disc Of 0o Stock
157. rmination point 15 Verify the jumper on the motor is located on the same pins as the motor that was replaced 16 Turn power to the heater on 17 The screen will display system test The fault Fault Feedback Air Actuator will be displayed DO NOT RESET THIS FAULT YET Press Escape twice to clear the fault from the screen 18 Press Escape to get to the main menu Under Params amp Display Actuators Addressing select either the gas actuator or air actuator depending upon which was replaced The control will run an actuator check then display Start Address Assignment with ENTER Press Enter The display will then have you press the addressing button on the actuator This is the red button on the actuator The screen will then display Actuator Address Assignment Successful 19 Press Escape until the main menu is reached Under OperationStat Status Reset reset the fault Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 79 Caution The heater emissions may not be correct after changing the servo motor Verify the emissions throughout the range of modulation If emissions are off the servo motor can be adjusted by following the procedure in the Commissioning the Heater section of this manual 17 On Off Burner a The sequence of operation begins with power on limit switch and fuel valves closed and temperature controller calling for heat The fl
158. rom the port If flow has not started after two to five minutes remove the coupling guard and rotate the pump shaft by hand in the proper direction This should help move the cold viscous fluid through close tolerance seal areas Replace plug when flow is steady If this fails to induce flow introduce fluid through the bleed port and rotate the shaft by hand to work the fluid around the seal area Continue to add fluid and rotate the shaft until no more fluid can be added Replace the plug and run pump for five to ten seconds Stop the pump remove the plug and wait for flow to start If after two minutes flow has not started add more fluid as described above and run the pump for five minutes Constantly check the bearing area located immediately behind the casing for overheating Remove the plug and check for flow If flow has not started at this point the fluid may be too viscous to move through the seal area Start the system normally by selecting heat on the control panel and raise the temperature 50 F Continue to raise the system temperature by 50 F increments Keep checking the pump until flow starts Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 58 Caution 1 Use extreme caution opening plug when system temperature is elevated Wear eye and hand protection Back the plug out slowly to the last two or three threads Allow any pressure under plug to bleed slowly to prevent a s
159. rs 2 40 000707 1 1 2hp blower motor TEFC 208 480 60 3ph 50 0 22 0 Stock 2 40 000599 3hp blower motor TEFC 208 480 60 3ph 55 0 25 0 Stock 2 40 000622 5hp blower motor TEFC 208 480 60 3ph 2 40 00079 7 1 2hp blower motor TEFC 208 480 60 3ph 80 0 37 0 Stock 2 40 000870 10hp blower motor TEFC 208 480 60 3ph 168 0 76 3 Stock 2 40 000865 15hp blower motor TEFC 208 480 60 3ph 200 0 91 0 Stock 2 40 000840 20hp blower motor TEFC 208 480 60 3ph 316 0 144 0 Stock Fans Air Gate parts 2 30 000573 8 3 8 x 2 1 2 x 1 1 8 FT 0080 0120C 2 92 1 33 Stock 2 30 000561 9 3 16 x 3 x 1 1 8 FT 0160C 4 66 2 12 Stock 2 30 000562 9 15 16 x 3 x 1 1 8 FT 0160C amp 0240C 5 14 2 34 Stock 2 30 000419 10 5 8 x 4 x 1 3 8 FT 0400C Dual Fuel 5 14 2 34 Stock 2 30 000443 12 3 16 x 6 x 1 5 8 Stock 2 30 000563 10 5 8 x 4 x 1 1 8 FT 0240 0320 0400C 6 4 2 91 Stock 2 30 000564 10 5 8 x 1 1 8 FT 0600C 7 4 3 36 Stock 2 30 000444 10 5 8 x 1 3 8 FT 0600C 6 2 2 82 Stock 2 30 000571 12 3 16 x 6 x 1 3 8 FT 0800C amp FT 0600C dual fuel 1 72 78 Stock 2 30 001320 13 15 16 x 6 1 2 x 1 5 8 FT 1000 1200 1400C 0800C dual 17 9 8 14 Stock fuel Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 135 2 30 000560 9 3 16 x 2 1 2 x 1 1 8 4 4 2 0 Stock 2 20 000050 5 8 x 1 1 8 shaft adaptor 0 56 25 Stock 5 10 001850 7 8 x 1 1 8 575v shaft a
160. s 6 10 Pipe Diameters Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 20 b Location 1 The pump should be located adjacent to the heater Its base must be firm level preferably concrete and free from vibration c Connections amp Piping 1 The pump should be routed as per the manufacturer s requirements It should be equipped with flexible connections at the suction and discharge sides The primary function of these connections are to prevent stresses due to pipe expansion from being placed on the pump and to isolate pump vibrations from the pipe work and the heater They also allow for expansion and deflection of the pipe work These connections should be rated for high temperature since they are considered part of the piping system The suction pipe work must be directly connected to the deaerator section via a vertical run with as few elbows as possible and should contain the strainer and an isolating valve The discharge pipe work must be connected directly to the heater inlet and should contain an isolating valve See that pipe work connections match up accurately with pump flanges Refer to the pump manufacturer s recommendations for the specific pump inlet piping requirements Typically these requirements are that It be a straight run of pipe The straight run from the pump inlet to the first fitting valve or flex connector be a minimum of 6 10 pipe diameters i
161. s must not be made out of copper copper alloys aluminum or cast iron Cast iron is porous to thermal fluids and copper and aluminum act as catalysts in the degradation of some thermal fluids Carbon or stainless steel or ductile iron are recommended For standard applications all components must be rated to 650 F unless otherwise stipulated All pipework valves and user equipment must be suited to the maximum operating pressure of the heater The maximum pressure stamped on the heater nameplate is typically 150 psig 690 kPa If an isolating valve is completely closed the pressure in the system will rise to the deadhead pressure of the pump Suitably sized pipe will enable the system to withstand the total head generated by the circulating pump should this occur In applications where it is desirable to design to pressures lower than 100 psig an alternative safeguard is to install appropriately sized safety valves Where secondary circulating pumps are installed the system must be suitable for the aggregate head against a closed valve of both pumps During construction of the installation ensure that no dirt water or residue from welding is left in the system 14 Equipment a Heaters that are skid mounted with pumps and tanks are equipped with a y strainer a flex connector and a valve in the inlet run between the pump and the combination tank Piping between the discharge of the pump and the inlet of the heater will
162. s by a maximum of 0 5 at a time before verifying combustion 1 Goto Params amp Display RatioControl GasSettings CurveParams 2 Wait for the spinning line on the left to disappear Press Enter The number 1 should appear to the right of the cursor this is the Point Number 3 Press Enter once Select ChangePoint by pressing the arrow keys to highlight and then press Enter to select This will cause the servo motors to move to this low fire point Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 76 4 6 Check combustion and adjust the servo motors as required To adjust a servo motor arrow to it and press Enter Then adjust the setting as required and press Enter You can now adjust another servo motor if needed When combustion is properly set for that point press Escape once more If it asks you to store the point press Enter Note the AZL will only ask to save if either servo value has been altered Low fire is now set and stored e Setting the Complete Range 1 Remember it is only necessary to approximate the setting through the modulation range until high fire conditions are established Press Enter once more to have access to the point number field Increase the point number by one and press Enter Select ChangePoint and press Enter The servos will now move to that point Verify combustion is satisfactory Measure input or monitor last elbow pressure Verify
163. se of the High Inlet Pressure Switch is to protect the heater from building too high of a pressure Typical coil model heaters have a maximum working pressure of 150 psi with 100 psi safety valve s on the heater outlet manifold The High Outlet Pressure Switch should be set at 5 psi over the heater outlet pressure as read at ambient temperature assuming that none of the conditions mentioned below are true Tripped High Outlet Pressure Switch a An obstruction downstream of the heater 1 Any obstruction downstream of the heater will increase the pressure that the heater outlet sees This obstruction will generally result from an improper valve setting Observe heater outlet pressure at temperature with all users heat exchangers calling for heat 100 user Observe heater outlet pressure at temperature with all users heat exchangers not calling for heat 100 bypass Bypass regulating valve s should be adjusted to equal flow condition through users Call or e mail Fulton for further details It may be possible that an automatic control valve has failed If this is the case the valve should be replaced b Plugged coil pipe s 1 If too low of a flow condition has occurred for too long a period of time or if the maximum operating temperature of the oil has been exceeded it is possible however unlikely that a pipe or pipes in the coil could plug with solids If this occurs it will be necessary to shut down the system a
164. sed diaphragm switch that opens on a pressure decrease below set point The Low Gas Pressure Switch is a safety device that protects the burner from receiving too low of a gas pressure The switch senses this pressure just downstream of the gas regulator This switch will most likely trip at high fire If this switch trips it is generally one of the following issues y Gas pressure setting on the main regulator is too low 1 At high fire the modulating gas valve is full open resulting in the least amount of back pressure in the gas train With unit running at high fire check net last elbow gas pressure and compare to factory test fire sheet Net gas pressure is running gas pressure minus purge pressure Make sure net pressure reading is within 2 w c of factory reading If there is a difference adjust main regulator Adjust for proper combustion throughout range Z Gas orifice plate is damaged 1 If the orifice plate is damaged it may be holding back less gas creating a lower pressure on the sensing switch Pull burner and inspect gas orifice plate Plate should in no way be warped or degraded If it is replace After reinstallation recheck input and adjust combustion throughout range aa Gas pressure switch setting is improper 1 If above two items are proper check the pressure that the low gas pressure switch is sensing by way of a tee installed in the line Hold unit at high fire and check pressure Setting o
165. servo motor The model number starts with the letter SQM and is displayed on a label on the side of the motor Once the new motor has been verified to be correct turn power to the heater off Turn off all electricity to the heater Remove the cover on the servo motor to be changed Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 78 5 Remove the green wiring plugs and the conduit termination point from the motor by pulling them towards you A black grounding wire runs from the motor to the conduit termination point Pull it off from the conduit termination point Also note the location of the jumper of the left side of the motor Loosen the allen screws on the motor end of the motor end of the motor to valve coupling 8 Unbolt the motor from the mounting bracket and remove the motor 9 Turn the valve so it is in the closed position and can rotate clockwise to open 10 Mark the coupling or valve shaft if needed so the position of the valve can be determined when the servo motor is installed 11 Bolt the new servo motor on to the mounting bracket with the motor shaft inserted into the coupling 12 Rotate the valve shaft coupling assembly closed as stated above 13 While holding the valve closed tighten the allen screws on the coupling 14 Install the wired green wiring plugs and the conduit termination point on the new motor Connect the black grounding wire form the motor to the conduit te
166. ses flame while driving to a point then Turn the main ON OFF switch to OFF Reset the loss of flame fault Press Escape on the AZL once Press Enter on the AZL to reset the control The red light on the panel box door should go out Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 75 d e Adjust the air and gas servos for that point while the burner is off Follow steps d1 d2 below Turn the main ON OFF switch to ON 3 Under Params amp Display RatioControl GasSettings ProgramStop change the program stop to deactivated by using the arrow keys Confirm that deactivated is acknowledged in the current field 4 This change will allow the burner to modulate The burner will now drive to low fire Remember it is only important at this stage to set low fire to be stable and with clean combustion Exact setting is to be performed once high fire is confirmed Press Escape 5 times to get back to the main menu You can observe the status of the burner By going to OperationalStat NormalOperation 7 Verify the flame signal on the display measure input if gas meter is available If not match last elbow pressures and combustion for test fire sheet Adjust the burner as needed To adjust the servo position follow steps 1 2 below Setting Low Fire Note As soon as a servo position is altered the servo will move to that position Only change servo setting
167. so result in thermal fluid breakdown Fulton heaters are equipped with a temperature limit switch located on the front of the panel box to prevent this from occurring 5 A high temperature limit switch acts as an over temperature safety device If the high temperature limit shuts down the unit the manual reset button on the limit switch must be pressed The reset button on the flame programmer must also be pressed to reset the unit before it can be restarted Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 52 ection 3 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 53 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 54 Section 3 Operation 1 Start Up Preparation amp Installation Review a b Check with local authorities where approval for start up is required In some localities final inspection of services may be required Review the installation section of this manual carefully Confirm accordance with installation guidelines including 1 In general ensure that the heater area is in conformance with established heater room requirements Review national and local codes 2 Preparation a Check for total absence of water in pipework and fluid To help the system open all drains blow air nitrogen if available into a high point bleed through a pressure regulating valve Note Unless s
168. sure that the temperature setpoint is as desired On gas units pilot valve activation will be indicated after pre purge cycle has completed followed by main flame activation Check the presence of the flame by observing flame signal strength from flame programmer or testing device Operator attendance during warm up is a recommended precaution Start up is considered complete when the unit begins to throttle back or shutdown on target temperature 22 Daily Shutdown Set control switch to Pump pump running burner off Allow the fluid to circulate for approximately 20 30 minutes and then set the control switch to the Off position When using fluid cooled pump continue to circulate cooling water to pumps for 30 minutes after stopping circulation Open power supply switches Units switched off by an automatic time switch should have an extra relay fitted to allow 20 30 minutes of fluid circulation after stoppage in order to prevent localized over heating of fluid Close fuel valves if required Closing of system valves is not generally necessary unless maintenance of components requires a partial draining of the system Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 89 g Because of the high temperatures usually applied leaks are not expected to occur when cool down is achieved provided pipework is free to contract naturally when cold Fulton Thermal Corp Vertical Coil Thermal Fl
169. switch will shut the unit down in the event of loss of flow The differential pressure switch can be tested while only the pump is running Remove the metal cover on top of the switch and increase the setpoint until the pump shuts down Next decrease the setpoint back to its initial value and depress the pump start button to verify the pump will re start P ns lt lt a y MAMA SO Los Differential Pressure Switch f Pump Motor Starter 1 While firing actuate the manual trip button on the pump motor starter Pump and burner will shut down The blower should continue to run for approximately thirty seconds Attempt to restart pump by setting the selector switch to Pump and depressing the pump start push button The pump should not start Reset starter and start pump g High and Low Fluid Pressure Switches 1 The only pressure required in the thermal fluid system is the pressure required to maintain the proper flow Pressure changes are monitored with these switches which will shut the unit down in case of a change in the fluid flow Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 83 With three position switch set to Pump remove the cover from the pressure switch and manually activate Pump should shut down Repeat for each switch replace covers Note if the burner was on it would also stop To set the low fluid pressure cutout switch raise the setpoint with the f
170. t Valves used on NFPA85 Fuel Trains 2 30 000296 v2 Pilot Vent Valve Stock 2 30 000400 Vent Valve 8215G33 1 8 81 Stock 2 30 000401 1 Vent Valve 8215C53 3 78 1 71 Stock 2 30 000402 1 1 4 Vent Valve EF8215C63 5 18 2 35 Stock 2 30 000458 NEMA 4 Vent Valve EF8215C33 4 58 2 08 Stock 2 30 000447 1 NEMA 4 Vent Valve EF8215C53 4 6 2 09 Stock 2 30 000446 1 1 4 NEMA 4 Vent Valve EF8215C63 4 6 2 09 Stock Butterfly Valves 2 30 000508 1 Gas Butterfly Valve Eclipse 2 2 1 0 Stock 2 30 000509 1 1 4 Gas Butterfly Valve Eclipse 2 3 1 05 Stock 2 30 000510 1 1 2 Gas Butterfly Valve Eclipse 2 74 1 25 Stock 2 30 000511 2 Gas Butterfly Valve Eclipse 4 0 1 82 Stock 2 30 000512 3 Gas Butterfly Valve Eclipse 8 34 3 79 Stock 2 30 000533 24 Pilot Flex Hose 42 19 Stock 2 30 000572 18 Pilot Flex Hose 36 16 Stock 2 30 000575 24 CGA Flex Hose 36 16 Stock 2 30 000570 V2 x 36 Flex Hose Stock Oil Pumps 2 30 000127 Oil Pump V023C 40M20 8 34 3 79 Stock 2 30 000212 Oil Pump 18B1H2FX 5B Consult Factory 12 78 5 81 2 30 000525 Oil Pump 22R2210 5C3 6 82 3 1 Stock 2 30 000526 Oil Pump 22R623C 5C14 8 7 3 95 Stock 2 40 001659 3 4hp TEFC C Face motor 208 230 460 3ph 20 62 9 37 Stock 5 20 400199 Mounting Bracket Motor Pump 4 0 1 82 Stock Oil Valves 2 30 000513 N A Oil Valve 2 516 9 54 4 34 Stock 2 30 000606 Hauck Oil Valve S32C 2 02 90 Stock 2 30 000605 Hauck Oil Valve S33C 2 46 1 12 Stock 2 30 000514 Hauck Oil Valve S35C 2 52 1 15 Sto
171. t protects the burner from receiving too high of a gas pressure The switch Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 120 senses this pressure downstream of the last gas valve upstream of the modulation valve on units that modulate This switch is most likely to trip at low fire If this switch trips it is generally one of the following issues s Gas pressure setting on the main regulator is too high 1 With unit running at high fire make sure that the modulated gas valve is at full open Note Since unit lights at low fire it may be necessary to increase high gas pressure setting or jumper contacts to allow unit to modulate to where modulation gas valve back pressure is lessened Check net last elbow gas pressure and compare to factory test fire sheet Net gas pressure is running gas pressure minus p urge pressure Make sure net pressure reading is within 2 w c of factory reading If there is a difference adjust main regulator Adjust for proper combustion throughout range t Low fire gas valve setting is too low 1 Because the sensing point of the High Gas Pressure Switch is upstream of the modulating gas valve the highest pressure read will occur during low fire Check net last elbow gas pressure and compare to factory test fire sheet Net gas pressure is running gas pressure minus purge pressure Make sure net pressure reading is within 1 w c of fa
172. tchment Expansion Volume Expansion Tank Liquid Fluid In W Thermal Level U Buffer Switch Section Deaerator Section BB Hot Fluid E Medium Fluid E Cool Fluid E Gases Steam Fluid Out Drain Model Capacity Initial Fill Available for Max System Gallons Gallons Expansion Volume Gallons FT 200 L 52 25 46 184 FT 500 L 132 40 121 525 FT 1000 L 264 80 232 1000 FT 1500 L 397 90 380 1400 FT 2000 L 528 145 444 1700 FT 3000 L 793 215 717 2600 FT 5000 L 1310 300 1168 4600 9 Pressurized Systems a Nitrogen pressurization may be used to advantage where the total system content is very large or in a system operating near or above the vapor pressure of the fluid employed or if the inlet of the DA tank is not the highest point in the piping system In conjunction with this system an automatic venting device must be fitted to the system expansion tank Consult Fulton Thermal Corporation for further details The location for the liquid level switch is a 2 1 2 NPT connection on the same end of the tank as the inlet The liquid level switch is supplied and shipped with the unit and must be installed by the customer and then wired to the control panel Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 27 Note If the tank is located outdoors nitrogen is required Liquid Level Switch 10 Connections a The vent connecti
173. th all users heat exchangers calling for heat 100 user Observe heater outlet pressure at temperature with all users heat exchangers not calling for heat 100 bypass Bypass regulating valve s should be adjusted to equal flow condition through users Call or e mail Fulton for further details It may be possible that an automatic control valve has failed If this is the case the valve should be replaced b Plugged circulation pump strainer basket 1 A plugged strainer will result in a decrease in flow through the heater High vacuums developed from plugged strainers can also stress the seals of the pump causing the pump to fail A Pump Suction gauge is provided on Fulton Thermal skids to help determine when a strainer needs cleaning Generally this point is 5 10 psi 10 20 in Hg If the strainer is plugged isolate the strainer and drain being mindful of the temperature of the thermal fluid Remove the strainer and clean with compressed air high pressure water or a cleaning solution Replace and observe new heater inlet pressure c Failed circulation pump coupling 1 A failed coupling will result in a decreased or no flow condition through the heater The coupling can be checked by removing the coupling guard between the pump and pump motor The coupling should not be torn or misshapen If the coupling needs Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 114 to be replaced
174. that these points are in general correspondence with the test fire sheet Repeat step 2 until the point position has a load value of 100 You are now at high fire Verify combustion is per test fire sheet Once at high fire adjust the incoming gas pressure at the main gas regulator to match the test fire report Adjust the gas servo motor to change the last elbow pressure to match the test fire report Adjust the air servo motor to adjust the emissions as needed Repeat step d1 but start at the high fire point number Continually decrease the point number after combustion has been verified at each point Once all the points have been verified press Escape until you are back to the main menu You can observe the status of the burner by going to OperationalStat NormalOperation Turn the main ON OFF switch to OFF The control will now postpurge Follow steps 16a3 17 and b1 4 again to verify ignition with the new gas pressures Turn the main burner switch to OFF The control will now post purge Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 77 13 14 Under Manual Operation Auto Manual Off change the operation to Automatic and press Enter and confirm Automatic is entered in the current field Press Escape twice to get back to the main menu Under Updating ParamBackup select LMV51 AZL This will store all of the adjustments that have been made in the LMV base modul
175. the means of sensing the main flame strength has failed During the main flame proving period the flame programmer must sense a strong enough flame to hold the main valves open If you are experiencing Main Flame Failures check the following items d Main flame strength is inadequate 1 Cycle the unit During the main flame proving period carefully observe the pilot flame strength Current controls are supplied with a test switch that can hold the programmer in the main flame proving period If a main signal is greater than 0 0 but less than the minimum required is detected look through the observation port to try to visibly see flame A combustion change may be necessary to establish main If observed flame is blue slightly decrease the air damper setting and recycle If flame is red or orange slightly increase air damper setting and recycle Once adequate flame signal is established reset input and combustion throughout range of modulation e Flame sensing device does not work properly 1 Cycle the unit If a signal of 0 0 is detected look through the sight hole provided on the burner plate of the heater to Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 125 visibly detect flame If flame is seen your flame detection device or amplifier may be faulty If the unit has a flame rod lockout and tag heater s electrical circuit and fuel supply Pull pilot assembly out of unit I
176. uid Manual Version 2009 0929 Page 131 1 Sight Glass 2 11 000107 Peep Hole Casting 0 15 0 06 Stock 2 12 000014 1 Pyrex Disc 0 02 0 01 Stock 2 12 000015 Peep Hole Gasket 0 03 0 01 Stock 3A Sight Glass 2 12 000012 Flame Sight Glass 0 05 0 01 Stock 2 30 000568 1 Air Hose Stock 2 30 000569 1 clamp Stock 2 30 000924 Ring Screw 0 0 0 0 Stock 2 30 000925 Ring Nut 0 0 0 0 Stock 2 30 000910 FT 0080 0120 0160 C Outer Ring 1 76 0 8 Stock 2 30 000911 FT 0240 0320 C Outer Ring 2 72 1 24 Stock 2 30 000912 FT 0400 C Outer Ring 4 6 2 09 Stock Miscpart FT 0600 C Outer Ring 7 0 3 18 2 30 000926 Cone Screw 4 required 0080 0320C 8 required 400C and up 0 0 0 0 Stock 2 20 000185 Cone Spacer 035 for FT 0080 C 4 required 0 0 0 0 Stock 2 20 000184 Cone Spacer 079 for FT 0120 0160 0240 0320 C 4 required 0 0 0 0 Stock 2 20 000183 Cone Spacer 114 for FT 0400 C 8 required 0 0 0 0 Stock 2 20 000182 Cone Spacer 121 for FT 0600 0800 C 8 required 0 0 0 0 Stock 2 30 000909 Flame Cone FT 0080 C w ring 2 88 1 31 Stock 2 30 000664 Flame Cone FT 0120 C amp FT 0160 C w ring 5 22 2 37 Stock 2 30 000665 Flame Cone FT 0240 C w ring 4 88 2 22 Stock 2 30 000666 Flame Cone FT 0400 C w ring 10 52 4 78 Stock 2 30 000667 Flame Cone FT 0600 C w ring 13 38 6 08 Stock 2 30 000668 Flame Cone FT 0800 C w ring 28 3 12 9 Stock 2 30 000670 Flame Con
177. uid Manual Version 2009 0929 Page 90 ection 4 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 91 Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 92 Section 4 Maintenance Minimum equipment necessary to start and maintain fuel fired thermal fluid heaters e Digital Multimeter e Combustion Analysis Equipment e Draft Gauge 1 Required Maintenance at First Shutdown a The thermal fluid system should be shut down after no more than 24 hours of operation at operating temperature At this time the following maintenance items will need to be completed to meet the condition of warranty b While pump is still at operating temperature align circulating pump s to pump manufacturer specifications This should be done by means of a dial indicator c Isolate Y strainer s in system and clean regardless of pump suction pressure Make sure that the temperature is low enough to handle safely or provision has been made to handle materials at high temperature Generally temperatures below 150 F are acceptable to perform operation with regular work gloves d With piping system at ambient temperature torque all bolts on skid and throughout system to gasket manufacturer specification using proper flange torquing practices incremental torque increases star pattern etc These values are available in the installation section of the manual e Visually inspect all thread fitt
178. ure water or a cleaning solution Replace and observe new pump suction pressure Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 108 e Failed circulation pump coupling 1 A failed coupling will result in a decreased or no flow condition through the heater The coupling can be checked by removing the coupling guard between the pump and pump motor The coupling should not be torn or misshapen If the coupling needs to be replaced it is recommended to re align the circulating pump first at ambient temperature and again when it s at operating temperature Alignment should be within pump manufacturers specifications f Cavitation of the circulating pump 1 g System is Open Cavitation occurs when a pump experiences a loss of head or if any low heater flashes to gas at the impeller During this time the pump impeller spins without actually circulating any thermal fluid If Fulton Thermal Corporation provided the heater skid loss of head to the pump is extremely unlikely with proper fluid level in the combination tank The most common low heater in a thermal piping system is water which needs to be boiled out at startup or anytime new piping or fluid is added to the thermal oil system Once the system has been brought up to full operating temperature assuming that the entire system has seen flow there should be no further occurrence of low heater contamination apart from possible heat
179. urpose of the High Outlet Pressure Switch is primarily to protect the heater from building too much pressure Typical coil model heaters have a maximum working pressure of 150 psi with 100 psi safety valve s on the heater outlet manifold The High Outlet Pressure Switch should be set at 5 psi over the heater outlet pressure as read at ambient temperature assuming that none of the conditions mentioned below are true A tripped High Outlet Pressure Switch is an indication of one of the following and will require the manual reset button on the switch to be pushed I An obstruction downstream of the heater 1 Any obstruction downstream of the heater will increase the pressure that the heater outlet sees This obstruction will generally result from an improper valve setting Observe heater outlet pressure at temperature with all users heat exchangers calling for heat 100 user Observe heater outlet pressure at temperature with all users heat exchangers not calling for heat 100 bypass Bypass regulating valve s should be adjusted to equal flow condition through users Call or e mail Fulton for further details It may be possible that an automatic control valve has failed If this is the case the valve actuator should be inspected and possibly replaced Fulton Thermal Corp Vertical Coil Thermal Fluid Manual Version 2009 0929 Page 110 m Improper switch setting 1 n Faulty Switch 1 o Flow Switches 1 The Hig
180. ut not on normally open contact either switch contacts if another set of normally open contacts are available or replace relay a The burner interlock is the electrical circuit that enables the flame programmer Your thermal heater needs to have the items in the burner interlock made before ignition can occur Items in the burner interlock may include an air switch air filter switch auxiliary blower motor starter contacts high temperature limit s high gas pressure switch low gas pressure switch and or low oil pressure switch b Air Switch All C model heaters have an Air Switch This is a normally open switch that closes with proper burner fan outlet pressure This switch is generally a diaphragm type switch The Air Switch is a safety device that proves that there is an adequate pressure and volume of make up air for proper combustion and mixing There is no manual reset on the air switch itself to indicate a trip The most likely time of an air switch trip is at low fire purge or low fire If this switch trips it is generally one of the following issues c The combustion blower fan is dirty 1 If the cups of the squirrel cage type fan become dirty less air will be moved by the fan If the fans are dirty enough there will not be enough air flow for the air switch to prove You should assure that the combustion blower fan is clean reset the flame programmer and try to light unit again d The sensing line

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