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OPERATING, MAINTENANCE and SPARE PARTS MANUAL

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1. a 111 Lu III nc ESd 54 254 SE gt gt FTI 2 F 569 209 x E o pz 4 5 23 J RBC Standard Manual 04 2011 51 Fulton 7000 90444 606091 TIL 0 oN DNIMVSQ 31 0 GJAOHddAV 03423H2 NM VO 38910 sy1oM Jojiog uojng uoyny A INO 543108 SVD 404 11391 10JINOJ Y4Nand TANVd 00062994 009299 431 VM MOT L 9 STIVNINYSL N33A 138 34IM SAV 134 13 31 XVUldS ONISN dl LMI 9 8S SIVNIWHIL N334138 SAV 138 13 31 21 NIS d 000090883 DNIMVHO OL 44444 NOILIMA4 LSNI NOLEVANILNOJ LINJAN 404 NI 38 8 111 gt 5 zt lt 22 29 69 Get c c FA 4 9 2 D 2 AA 9 ESd lt EI gt L d 84 J14NSSI4d HDIH SddNana O T IH 404 CSd Lla Sa3Nana DNILV INQOW 404 480 113 Aa 6 ILUN 445 74 c rn a a zm 014 m C No 3 a en V AJ gt 430 IHJINI 4315008 SVD DA 1d Nid L A 0114 49 YO Y X ch 5 CAM NJ 8415004 aJNang E 441104 23 52 RBC Standard Manual 04 2011 9 9000 90444 606071 1 0 58317108 1304 304 JASSI ES 2 m FT 03433H3 NMVAQ LND 1041 0 4 pri 38919 29108 YOUNG v4 0006284 009289 1
2. Od OO AN A SBN Quantity A N A A A sch sch Assy Description 300RD140SX RBC3000 DUAL FUEL Assy No Description 300RD140UK 000 DUAL FUEL Part No 11786 11824 12413 13826 14465 10423 12444 12412 13303 13296 14588 12992 OGORD324SX 13069 14822 12456 13293 14668 5 2000 SA3010 12597 13123 13274 13037 13033 12449 14703 Part No 11824 12412 12413 13826 14465 13069 13123 13274 12449 12456 15004 10423 13037 SA3010 060RD324UK 11786 13277 13293 13296 12992 14589 5 2000 14588 13303 Fulton RBC3000 DUAL FUEL SX Spirax UK Standard Description GASKET 25mm PN16 IBC GASKET 15mm PN16 IBC GASKET 40mm PN16 IBC VALVE CHECK 1 1 4 RK41 E VALVE GLOBE BRONZE 1 2 PROBE BRASS 36 LONG GAUGE REFLEX CLIFTON 350 GASKET 32mm PN16 IBC VALVE BLOWDOWN 40mmKBV20 BRUSH HANDLE 3250mm BURNER D F MDFL 3300 41 GASKET 125mm PN16 IBC PANEL D F 75 180 AOTC FACIA FULTON FR HOR 3mm VALVE SAFETY DN50 11 2 GAUGE PRESSURE 6 200PSI BRUSH TUBE 44mmSINGLE PUMP WATER CR5 26 CLIFTON SAMPLE COOLER PRESSURE GAUGE ASSY PROBE BODY LP30 HIGH GASKET 65mm PN16 IBC VALVE DN125 ANGLE PAT N GASKET 100mm PN16 IBC PROBE TIP 1000mm LP30 SWITCH DOOR LIMIT DB4 VALVE STOP FLANGED DN40 Description GASKET 15mm PN16 IBC GASKET 32mm PN16 IBC GASKET 40mm PN16 IBC VALVE CHECK
3. OPERATING MAINTENANCE and SPARE PARTS MANUAL RBC Series HORIZONTAL STEAM BOILERS RBC Standard 04 2011 Fulton For Your Safety The following WARNINGS CAUTIONS and NOTES appear in various sections of this manual WARNINGS must be observed to prevent serious It is the responsibility and duty of all personnel injury or death to personnel involved in the operation and maintenance of this equipment to fully understand the WARNINGS CAUTIONS must be observed to prevent damage or CAUTIONS and NOTES by which hazards are to be destruction of equipment or loss of operating eliminated or reduced effectiveness Personnel must become familiar with all aspects of NOTES must be observed for essential and effective safety and equipment prior to operation or operating procedures conditions andasastatement maintenance of the equipment to be highlighted N WARNING Steam Boilers are a potential hazard possiblv fatal if not properlv maintained A CAUTION It is vitally important that the instructions given in this manual are strictly adhered to Failure to carry out the routine maintenance checks could result in a drastic reduction in the life expectancy of the boiler NOTE The Pressure system and Transportable Gas Containers Regulations 1989 Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme and Section 40 of the Health and Safety at Work in 1974 Regular inspections are therefore required by
4. Phosphate Silica 17 118 4 10 grains hardness ppm It is critical that the boiler water is alkaline and within the range 10 5pH 12 0pH Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids TDS Consult your Water Treatment specialist to establish the frequency and duration of blowdown required to achieve the required water conditions RBC Standard Manual 04 2011 48 90073 KANN 581109 1304 Tang 4711590 HA KIK al Ate d Y deit Al 11112 412 Add dns y emi ma na LORI 000c592 00528 1131 114 dll 3114 41 n 4315009 H YOJOW v HOLOH YO LOI 50 dhd 03314 dhd 0333 HHH HAH 03003 49 Ji Addons 1 T 9 EE 5 141114 Sl 1114 41 HOU 3v INI 1 Tg HO HOLOW H did fid 8101 v did III nmm TIH 85 LLI ala HOLOW dnd al E A ldd is J5 Hd 3J10H15 IN He j lt kl wv llL LL 9 T T SLC E ERA E 7 m ON gn LIME TORNOS i L dHena 0 11318 03910733 LHI RBC Standard Manual 04 2011 49 Fulton 5 4 WIRING DIAGRAMS continued kal LH e No HI Mid ALTA Men pug JHNSSAHA HBIH T 4 22 Juv 14 E J kI ge gt Ji 14 g E puz gt 9015 11043 AQT ES m Ld 2 1 24531 837108 1
5. Description RBC 1500 NAME PLATE RB1500 DOOR WRAPPER PLAT GAUGE SYPHON PIGTAIL 1 4 TEE BRONZE 1 4 EQUAL PROBE BRASS 36 LONG PUMP WATER CR3 25 HAND MANHOLE ASSEMBLY TUBE 1 4 OD COPPER SOFT SWITCH DOOR LIMIT DB4 RB BRUSH HANDLE 3250mm ANGLE M S 60x60x 6mm RB1500 DOOR INSULATION FACIA FULTON FR HOR 3mm VALVE DN100 ANGLE PAT N VALVE GLOBE BRONZE 1 2 VALVE CHECK 1 1 4 RK41 E VALVE BLOWDOWN 32mmKBV20 GAUGE REFLEX CLIFTON 350 GAUGE PRESSURE 6 200PSI VALVE SAFETY DN32 11 2 RB BRUSH HANDLE 2300mm RB BRUSH TUBE 38mmSINGLE TURBULATOR RB 150090 BURNER OIL NOL 85 38 T3L VALVE STOP FLANGED DN32 Quantity AQ AN NN Q AN a a a a Fulton RBC1500 OIL SX Spirax UK Standard Assy No Description Part No Description Quantity 150RO140SX RBC1500 OIL BOILER SA2000 CLIFTON SAMPLE COOLER 1 14678 BURNER OIL NOL 60 34 T3L 1 13294 BRUSH HANDLE 2950mm 1 13826 VALVE CHECK 1 1 4 RK41 E 1 13292 BRUSH TUBE 38mmSINGLE 1 13277 VALVE STOP FLANGED DN32 1 14465 VALVE GLOBE BRONZE 1 2 2 13069 FACIA FULTON FR HOR 3mm 1 060RO324SX PANEL OIL 75 180 AOTC 1 10423 PROBE BRASS 36 LONG 2 13209 VALVE DN 100 ANGLE PAT N 1 12412 GASKET 32mm PN16 IBC 6 12456 GAUGE PRESSURE 6 200PSI 1 13080 GASKET MAN H 305x400x25 1 13033 PROBE TIP 1000mm LP30 2 12449 SWITCH DOOR LIMIT DB4 1 11786 GASKET 25mm PN16 IBC 5 11824 GASKET 15mm PN16 IBC 3 13016 VALVE BLOWDOWN 32mmKBV20 1 14291 PUMP WATER CR3 25 1 13037 GASKET
6. GASKET 25mm PN16 IBC GASKET REFLEX B7 VALVE BALL 1 2 SPECIAL GASKET H H 7 x 5 x 3 4 RB BRUSH TUBE 38mmSINGLE VALVE BALL 1 4 SPECIAL GASKET 15mm PN16 IBC GASKET 65mm PN16 IBC VALVE BALL 3 4 2 PIECE RBC Standard Manual 04 2011 Quantity ab GQ AO AN AQ AN Quantity N AN NN N FAN ANY 76 RBC1000 DUAL FUEL BOILER SX Spirax UK Standard Assy No Description 100RD140UK RBC1000 DUAL FUEL TT 11824 060RD324UK 11608 SA3010 11786 13424 Description GASKET 100mm PN16 IBC VALVE GLOBE BRONZE 1 2 BRUSH HANDLE 2950mm PROBE BRASS 36 LONG FACIA FULTON FR HOR 3mm VALVE BLOWDOWN 25mmKBV20 PUMP WATER CR3 21 SWITCH DOOR LIMIT DB4 BURNER D F MDFL1880 T3D VALVE SAFETY DN32 50 ARI GAUGE PRESSURE 6 200PSI BRUSH TUBE 38mmSINGLE GASKET 32mm PN16 IBC GASKET 65mm PN16 IBC VALVE STOP FLANGED DN25 CLIFTON SAMPLE COOLER VALVE DN65 ANGLE PATTERN GASKET 15mm PN16 IBC PANEL D F 60 180HP AOTC VALVE CHECK 1 RK41 E S PRESSURE GAUGE ASSY GASKET 25mm PN16 IBC LABEL RB REGISTRATION RBC Standard Manual 04 2011 Quantity sch sch N cA RPE A N Fulton RBC1000 GAS BOILER SX Spirax UK Standard Assy No Description 100RG140SX RBC1000 GAS BOILER Assy No Description 100RG140UK RBC1000 GAS BOILER Part No 12449 O60RX324SX 15002 12412 12456 13276 11608 12597 14797
7. To store the boiler in a corrosion free situation there are three practical solutions as follows a b Fully flood the boiler to exclude as much air as possible Drain the boiler completely Remove all hand hole and man hole doors Open all gas oil side access doors refer to the maintenance section As b but also introduce a form of convection heating to the gas oil and water side A very effective solution is to install a string of outdoor type waterproof light bulbs distributed throughout the boiler 3 10 EVAPORATION TEST This test may be required by your insurance inspector as part of the annual inspection a b With the burner running switch off the boiler feedpump and allow the water level in the boiler to lower by evaporation When the water level reaches the 1st low water position an alarm will sound the 1st low water indicator lamp will illuminate and the burner will stop Allow the evaporation process to continue until the 2nd low water alarm sounds and the 2nd low water alarm switch illuminates Switch the feed pump to the pump amp burner on position The water level will be restored to normal working level the 1st low water indicator lamp will extinguish and the alarm will cancel Press the 2nd low water alarm reset switch The 2nd low water alarm reset switch will extinguish the alarm will cancel and the burner will start Note Because the burner shuts down during this test it
8. 5 2000 14821 14293 11824 14646 Fulton Description RB BRUSH TUBE 44mmSINGLE GAUGE REFLEX CLIFTON 350 VALVE STOP FLANGED DN32 SWITCH DOOR LIMIT DB4 VALVE DN100 ANGLE PAT N FACIA FULTON FR HOR 3mm GAUGE PRESSURE 6 200PSI WASHER FLAT M10 PLATED WASHER FLAT M12 PLATED PROBE TIP 1000mm LP30 GASKET 40mm PN16 IBC PANL GAS 110V CTRL 415V GASKET 25mm PN16 IBC VALVE GLOBE BRONZE 1 2 RB PRESSURE GAUGE ASSY GASKET 32mm PN16 IBC GASKET 65mm PN16 IBC GASKET 100mm PN16 IBC PROBE BODY LP30 HIGH RB BRUSH HANDLE 3250mm VALVE BLOWDOWN 32mmKBV20 VALVE CHECK 1 1 4 RK41 E PROBE BRASS 36 LONG CLIFTON SAMPLE COOLER VALVE SAFETY DN40 11 2 PUMP WATER CR5 20 GASKET 15mm PN16 IBC BURNER GAS XGN2350 38 RBC Standard Manual 04 2011 Quantity 1 2 4 2 1 1 1 1 1 1 6 2 1 1 9 2 1 5 1 3 2 1 1 1 4 1 1 1 3 1 94 RBC1850 GAS BOILER SX Spirax UK Standard Assy No Description Part No 185RG140SX RBC1850 GAS BOILER 12413 13123 13037 13069 12412 12449 O60RX324SX 11824 14293 13033 14585 13826 12456 13209 11786 13016 SA3010 14465 15003 10423 13277 SA2000 13296 12597 Assy No Description Part No 185RG140UK RBC1850 GAS BOILER 10423 15003 12456 14585 13296 SA3010 11786 12413 13826 14293 13293 13217 12449 13037 13069 13016 12412 13209 060RX324UK 14465 13123 11824 SA2000 95 Fulton Description GASKET 40mm PN16 IBC GASKET 65mm PN16 IBC GASKET 100mm PN16 IBC FA
9. AN SN W AN a a a Quantity lA 2 lA N A S S S AN 78 Fulton RBC1000 OIL BOILER SX Spirax UK Standard Assy No Description Part No Description Quantity 100RO140SX 1000 OIL BOILER SA2000 CLIFTON SAMPLE COOLER 1 11786 GASKET 25mm PN16 IBC 10 10423 PROBE BRASS 36 LONG 2 OGORO324SX PANEL OIL 75 180 AOTC 1 13033 PROBE 1000mm 2 13424 LABEL RB REGISTRATION 1 13037 GASKET 100mm PN16 IBC 2 13276 VALVE STOP FLANGED DN25 1 14465 VALVE GLOBE BRONZE 1 2 2 12412 GASKET 32mm PN16 IBC 1 13075 VALVE DN65 ANGLE PATTERN 1 13123 GASKET 65mm PN16 IBC 2 12449 SWITCH DOOR LIMIT DB4 1 SA3010 PRESSURE GAUGE ASSY 1 13069 FACIA FULTON FR HOR 3mm 1 13292 BRUSH TUBE 38mmSINGLE 1 11608 VALVE CHECK 1 RK41 E S 1 12456 GAUGE PRESSURE 6 200PSI 1 15002 VALVE SAFETY DN32 50 ARI 1 14290 PUMP WATER CR3 21 1 13294 BRUSH HANDLE 2950mm 1 12597 PROBE BODY LP30 HIGH 2 14584 BURNER OIL NOL 50 34 T3L 1 13141 VALVE BLOWDOWN 25mmKBV20 1 Assy No Description Part No Description Quantity 100RO 40UK RB1000 OIL HORIZ SKID 13276 VALVE STOP FLANGED DN25 1 13075 VALVE DN65 ANGLE PATTERN 1 13123 GASKET 65mm PN16 IBC 2 13141 VALVE BLOWDOWN 25 20 1 13069 FACIA FULTON FR HOR 3mm 1 060RX324UK PANEL GAS 60 180HP AOTC 1 13424 LABEL RB REGISTRATION 1 12412 GASKET 32mm PN16 IBC 1 10423 PROBE BRASS 36 LONG 2 14465 VALVE GLOBE BRONZE 1 2 2 13292
10. JAVA GIONI10S XNV AN 03111441 XNV 8 34 8340 HILIMS 03501 608074 TIL d oN DNIMVUQ ALVG GIAQUddV 03323H2 NMVug aD SHOM 19 431114 41 0001 19 10 41 02 NMOaMOT9 5431108 1314 10 SYD LINDYID T3NVd 104103 NMOQM0 18 SQL 314405 JAVA 43110 1 02 01084105 501 TIV NO 43HL3D0L S SONIMVYA 01 33438 NOLLINAYLSNI NOLLVANILNOD XNV AN 04111441 XNV H 411114 3l 108103 501 038 NIVW ONIN V SV 11 5 000119 CL IWNINYAL ANY YSHLADOL S Li Lb TVNIN331 1JJNNOJ 5831108 FYON YO Z JO SNOILVTIVLSNI 401 ALON TVNIW331 03504 NI 544108 383 303 000090943 543104 531435 403 0000903 04 310N 48044 SAL inia 038 P 319V 038541425 J RBC Standard Manual 04 2011 59 sH3TIIDE 13 F 110 svn 4041 IA JAL TANT d 10341810 MOURI 18 0566 29 ONIA 0 310 U3333HJ 52 API o E ugnys TNL 115 4 sk 2 Ald dns TIGHLNAJ JATA JATHA HILI 01003103 040108 Nada 13501 501 fa lee S Molds TT 11849 03033915 3n1B Fulton NMDOMD TE 0 JH 11 1593 1199 299 404
11. 1 1 4 RK41 E VALVE GLOBE BRONZE 1 2 FACIA FULTON FR HOR 3mm GASKET 65mm PN16 IBC VALVE DN125 ANGLE PAT N SWITCH DOOR LIMIT DB4 GAUGE PRESSURE 6 200PSI VALVE SAFETY DN50 80 ARI PROBE BRASS 36 LONG GASKET 100mm PN16 IBC PRESSURE GAUGE ASSY PANEL D F 60 180HP AOTC GASKET 25mm PN16 IBC VALVE STOP FLANGED DN32 BRUSH TUBE 44mmSINGLE BRUSH HANDLE 3250mm GASKET 125mm PN16 IBC PUMP WATER CR5 24 CLIFTON SAMPLE COOLER BURNER D F MDFL 3300 41 VALVE BLOWDOWN 40mmKBV20 RBC Standard Manual 04 2011 Quantity NO A A A S S NO W Quantity oC OR ma 2 S Ogou 102 Assy Description 300RG140SX RBC3000 GAS BOILER Assy No Description 300RG140UK RBC3000 GAS BOILER 103 Part No SA3010 060RX324SX 12413 14766 5 2000 11824 12412 13277 14465 13293 12449 14589 15004 11786 10714 13274 13296 13303 12992 13033 10423 13037 13036 13069 12456 12597 13239 13826 14966 Part No 11786 14766 SA2000 13274 13277 13123 14465 SA3010 13069 13037 13293 13296 13303 10423 15004 14589 060RX324UK 12412 12413 12449 12456 12992 13826 Fulton RBC3000 GAS BOILER SX Spirax UK Standard Description PRESSURE GAUGE ASSY PANEL GAS 75 180 AOTC GASKET 40mm PN16 IBC BURNER GAS MGN3300 36T3L CLIFTON SAMPLE COOLER GASKET 15mm PN16 IBC GASKET 32mm PN16 IBC VALVE STOP FLANGED DN32 VALVE GLOBE
12. 100mm PN16 IBC 3 13123 GASKET 65mm PN16 IBC 1 12597 PROBE BODY LP30 HIGH 2 15002 VALVE SAFETY DN32 50 ARI 1 Assy No Description Part No Description Quantity 150RO140UK RBC1500 OIL BOILER 12412 GASKET 32mm PN16 IBC 6 14465 VALVE GLOBE BRONZE 1 2 2 12449 SWITCH DOOR LIMIT DB4 1 11824 GASKET 15mm PN16 IBC 3 11786 GASKET 25mm PN16 IBC 5 10423 PROBE BRASS 36 LONG 4 15002 VALVE SAFETY DN32 50 ARI 1 O60RO324UK PANEL OIL 60 180HP AOTC 1 12456 GAUGE PRESSURE 6 200PSI 1 13292 BRUSH TUBE 38mmSINGLE 1 SA2000 CLIFTON SAMPLE COOLER 1 13080 GASKET MAN H 305x400x25 1 13123 GASKET 65mm PN16 IBC 1 13294 BRUSH HANDLE 2950mm 1 13069 FACIA FULTON FR HOR 3mm 1 13277 VALVE STOP FLANGED DN32 1 14678 BURNER OIL NOL 60 34 T3L 1 13826 VALVE CHECK 1 1 4 RK41 E 1 14291 PUMP WATER CR3 25 1 13209 VALVE DN100 ANGLE PAT N 1 13016 VALVE BLOWDOWN 32mmKBV20 1 3 13037 RBC Standard Manual 04 2011 GASKET 100mm PN16 IBC 90 Assy 150ROA40UK RB1500 FULTON HORIZONTAL Assy No 150RPA40UK 91 Description Description FR1500 FULTON HORIZONTAL Fulton Part No SA3010 SA2040 120BD155XX 12449 060RX324UK SKIDX006 13016 11824 11786 HT T3000 12444 12456 14820 14291 SA2000 099CT301 13123 13239 13037 13069 13826 12412 13080 13277 13292 13294 10423 13209 14678 14465 13217 10483 Part No 12695 13111 SA0020 10483 11524 099CT301 14509 SKIDA150 120BD155XX RBC Standard Manual 04 2011 Description RB PRESSURE
13. 12449 SWITCH DOOR LIMIT DB4 1 13277 VALVE STOP FLANGED DN32 1 SA2000 CLIFTON SAMPLE COOLER 1 11824 GASKET 15mm PN16 IBC 3 13293 BRUSH TUBE 44mmSINGLE 1 13037 GASKET 100mm PN16 IBC 3 13016 VALVE BLOWDOWN 32mmKBV20 1 11786 GASKET 25mm PN16 IBC 5 12597 PROBE BODY LP30 HIGH 2 15003 VALVE SAFETY DN40 65 ARI 1 13209 VALVE DN100 ANGLE PAT N 1 13033 PROBE TIP 1000mm LP30 2 12456 GAUGE PRESSURE 6 200PSI 1 10423 PROBE BRASS 36 LONG 2 13296 BRUSH HANDLE 3250mm 1 13016 VALVE BLOWDOWN 32mmKBV20 1 SA3010 PRESSURE GAUGE ASSY 1 14465 VALVE GLOBE BRONZE 1 2 2 13826 VALVE CHECK 1 1 4 RK41 E 1 11824 GASKET 15mm PN16 IBC 3 10423 PROBE BRASS 36 LONG 4 12763 BURNER D F MDFL 2505 T3D 1 14293 PUMP WATER CR5 20 1 15003 VALVE SAFETY DN40 65 ARI 1 11786 GASKET 25mm PN16 IBC 5 060RD324UK PANEL D F 60 180HP AOTC 1 13037 GASKET 100mm PN16 IBC 3 12456 GAUGE PRESSURE 6 200PSI 1 SA2000 CLIFTON SAMPLE COOLER 1 13209 VALVE DN100 ANGLE PAT N 1 12449 SWITCH DOOR LIMIT DB4 1 13069 FACIA FULTON FR HOR 3mm 1 13296 BRUSH HANDLE 3250mm 1 13293 BRUSH TUBE 44mmSINGLE 1 13123 GASKET 65mm PN16 IBC 1 13277 VALVE STOP FLANGED DN32 1 12413 GASKET 40mm PN16 IBC 1 12412 GASKET 32mm PN16 IBC 5 93 RBC Standard Manual 04 2011 Assy 185RG100SX Description RB1850 SPRX 110V CTR 415 Part No 13293 12444 13277 12449 13209 13069 12456 10844 10845 13033 12413 060RX314SX 11786 14465 SA3010 12412 13123 13037 12597 13296 13016 13826 10423
14. 13293 13069 SA3010 11824 12413 12456 13826 12992 13037 SA2000 11786 13277 13274 12412 12449 15004 14590 13123 13242 13296 13303 14465 10423 Fulton RBC2500 OIL BOILER SX Spirax UK Standard Description VALVE DN125 ANGLE PAT N VALVE STOP FLANGED DN32 BURNER OIL NOL 100 38T3L VALVE GLOBE BRONZE 1 2 VALVE CHECK 1 1 4 RK41 E BRUSH TUBE 44mmSINGLE PUMP WATER CR5 22 VALVE SAFETY DN50 80 ARI PROBE BRASS 36 LONG PRESSURE GAUGE ASSY CLIFTON SAMPLE COOLER GASKET 15mm PN16 IBC BRUSH HANDLE 3250mm VALVE BLOWDOWN 40mmKBV20 GASKET 100mm PN16 IBC GASKET 25mm PN16 IBC GASKET 65mm PN16 IBC GASKET 125mm PN16 IBC GASKET 40mm PN16 IBC PROBE BODY LP30 HIGH GASKET 32mm PN16 IBC FACIA FULTON FR HOR 3mm PROBE TIP 1000mm LP30 SWITCH DOOR LIMIT DB4 PANEL OIL 75 180 AOTC GAUGE PRESSURE 6 200PSI Description PANEL OIL 60 180HP AOTC BRUSH TUBE 44mmSINGLE FACIA FULTON FR HOR 3mm PRESSURE GAUGE ASSY GASKET 15mm PN16 IBC GASKET 40mm PN16 IBC GAUGE PRESSURE 6 200PSI VALVE CHECK 1 1 4 RK41 E GASKET 125mm PN16 IBC GASKET 100mm PN16 IBC CLIFTON SAMPLE COOLER GASKET 25mm PN16 IBC VALVE STOP FLANGED DN32 VALVE DN125 ANGLE PAT N GASKET 32mm PN16 IBC SWITCH DOOR LIMIT DB4 VALVE SAFETY DN50 80 ARI PUMP WATER CR5 22 GASKET 65mm PN16 IBC BURNER OIL NOL 100 38T3L BRUSH HANDLE 3250mm VALVE BLOWDOWN 40mmKBV20 VALVE GLOBE BRONZE 1 2 PROBE BRASS 36 LONG RBC Standard Manual 04 2011 Quantity AO
15. 65mm PN16 IBC VALVE SAFETY DN32 50 ARI VALVE BLOWDOWN 25mmKBV20 Description GASKET 80mm PN16 IBC GASKET 32mm PN16 IBC GASKET REFLEX B7 VALVE BALL 1 2 SPECIAL VALVE BALL 1 4 SPECIAL GLASS REFLEX B7 CLIFTON GASKET 100mm PN16 IBC GASKET 65mm PN16 IBC GASKET HIH 7 x 5 x 3 4 GASKET 15mm PN16 IBC GASKET 25mm PN16 IBC GASKET MAN H 305x400x25 GASKET USE PART 13408 BRUSH TUBE 38mmSINGLE EYE GLASS 53mmx 3mm BELT G28017X FOR NUWAY RBC Standard Manual 04 2011 Quantity JN 3 3 3 3 3 AQ NO DB Quantity ND aee DS ENK oS ane 80 Assy 120RP140UK 81 Description RB1250 FULTON HORIZONTAL Part No 10423 13277 13217 14465 060RX324UK 13016 13037 SA3010 13069 13123 14290 13080 13292 15043 11824 13036 14820 13294 SA2000 11786 13826 12456 13209 12449 12412 RBC Standard Manual 04 2011 Fulton Description PROBE BRASS 36 LONG VALVE STOP FLANGED DN32 GASKET HIH 7 x 5 x 3 4 VALVE GLOBE BRONZE 1 2 PANEL GAS 60 180HP AOTC VALVE BLOWDOWN 32mmKBV20 GASKET 100mm PN16 IBC RB PRESSURE GAUGE ASSY FACIA FULTON FR HOR 3mm GASKET 65mm PN16 IBC PUMP WATER CR3 21 GASKET MAN H 305x400x25 RB BRUSH TUBE 38mmSINGLE BURNER PROPANE RS160 M GASKET 15mm PN16 IBC GASKET 80mm PN16 IBC VALVE SAFETY DN32 11 2 RB BRUSH HANDLE 2950mm CLIFTON SAMPLE COOLER GASKET 25mm PN16 IBC VALVE CHECK 1 1 4 RK41
16. CHECK 1 1 4 RK41 E 1 14659 PROBE BODY LP20 1 12444 GAUGE REFLEX CLIFTON 350 2 14589 PUMP WATER 5 24 1 SA2000 CLIFTON SAMPLE COOLER 1 15036 INSULATION REEL 1725x152 1 14465 VALVE GLOBE BRONZE 1 2 2 SA3010 PRESSURE GAUGE ASSY 1 13292 BRUSH TUBE 38mmSINGLE 1 13239 FLANGE 32mm WELDING S O 3 15005 VALVE SAFETY DN25 40 ARI 1 10418 PROBE BRASS 7 LONG 1 14661 PROBE PA20 PRE AMPLIFIER 1 14915 VALVE BALL 1 1 4 PN16 5 13277 VALVE STOP FLANGED DN32 1 13826 VALVE CHECK 1 1 4 RK41 E 1 14998 GAUGE TEMP 4 0 120DEGc 2 12412 GASKET 32mm PN16 IBC 6 12456 GAUGE PRESSURE 6 200PSI 1 11786 GASKET 25mm PN16 IBC 5 13123 GASKET 65mm PN16 IBC 1 13209 VALVE DN100 ANGLE PAT N 1 10566 GAUGE PRESSURE 4 250PSI 1 19097 GASKET 100mm PN16 IBC 3 13069 FACIA FULTON FR HOR 3mm 1 11824 GASKET 15mm PN16 IBC 1 14997 VALVE FEEDWATER DN32 MOD 1 13016 VALVE BLOWDOWN 32mmKBV20 1 10423 PROBE BRASS 36 LONG 3 12449 SWITCH DOOR LIMIT DB4 1 14986 BURNER GAS MGN2000LN M3D 1 15002 VALVE SAFETY DN32 50 ARI 1 060RM324UK PANEL GAS MOD WATER FEED 1 1 87 14181 RBC Standard Manual 04 2011 VALVE CHECK DN32 DCV2 Fulton RBC1500 GAS with MOD WATER SM Clifton SX Spirax UK Standard Assy No 150RG140SM Description RB1250 DUAL FUEL MW RBC1500 GAS SX Spirax UK Standard Assy No 150RG140SX Description RBC1500 GAS BOILER RBC Standard Manual 04 2011 Part No 10418 11824 SA3010 11786 12449 13037 060RM324SX 14659 14783 1244
17. FULTON FR HOR 3mm GASKET 100mm PN16 IBC ELBOW WI 1 2 GASKET 65mm PN16 IBC SWITCH DOOR LIMIT DB4 VALVE BLOWDOWN 25mmKBV20 GAUGE PRESSURE 6 200PSI VALVE DN65 ANGLE PATTERN RBC Standard Manual 04 2011 Quantity N N AO N A VY VY Quantity AQ B Q VY a a Assy 075RG140CH Description RBC750 GAS BOILER 075RG140CX RBC750 GAS BOILER Assy No Description 075RG140SX RBC750 GAS BOILER Part No 060RX324SX 12449 SA3010 11824 SA2000 11786 13080 14290 13075 14465 15001 13123 11608 13069 13291 10423 13141 13037 13033 13217 13276 13295 12597 13424 12456 12671 Description VALVE SAFETY DN25 11 2 VALVE BALL 1 4 ART 45T PIPELINE SET BCS1 1 2 TUBE 1 4 OD COPPER SOFT VALVE CHECK 1 RK41 E S GAUGE PRESSURE 6 200PSI GAUGE PRESSURE 6 200PSI PRESSURETROL 4 12BAR ELBOW 1 4BSP MALEx1 4 VALVE CHECK 1 RK41 E S MV11 SOLENOID VALVE 240V TOP COVER DANFOSS KPI36 VALVE SAFETY DN25 11 2 AIR SET 1 4 MPC2 0 BAR PROBE TIP 1000mm LP30 PROBE BODY LP30 HIGH VALVE BLOWDOWN DN25 PN40 VALVE BALL 1 4 ART 45T PIPELINE SET BCS1 1 2 Description PANEL GAS SWITCH DOOR LIMIT DB4 PRESSURE GAUGE ASSY GASKET 15mm PN16 IBC CLIFTON SAMPLE COOLER GASKET 25mm PN16 IBC GASKET MAN H 305x400x25 PUMP WATER CR3 21 VALVE DN65 ANGLE PATTERN VALVE GLOBE BRONZE 1 2 VALVE SAFETY DN25 40 A
18. INV 13 431109 Ant DNI1S31 SWd WOU4 yod Add A Z iJi 8 iJi 8 MM G3AOW3Y SI 43108 3H1 NO SY SSOUJY ANI JAL JYASNI TANVd SIHL ONILLIS NJHM 2 s ZI SIVNIWHAL TINVd 310438 1NVA318 01 123NNOO V 304 SV 3 3 4 FI 431109 404 SNOILIINNO TVNINYFL IWYS ISN L n 5 SILON e 01 1051 3505 12 ml 518405 sr SNIVH 431109 DW VZ 2 0 2 JW VZ 54 RBC Standard Manual 04 2011 Fulton 5 4 WIRING DIAGRAMS continued 8100 900 V al UH HU 031 113 10 Wav 4 d3lvm 11340 WI MG 38 188 h kull h ETT 114 D JAYO Maut JA FA E I dH 5 011 34 03 93108 0357 DHISUQ 111114 dll 03507 1 AGSSJHAWOJ UIUR7 ANYI HJIH aly 44 s a BB po 25 5 g aj U eo HOM EHII A 4 1800 4 10540 HOS ES 31014013 Way 14841014 dal HOH 4115 01105 L ALAND UHS 144111 11 Lait 3L MI Lands Lal did HILHA MOT NIE L MOT E MOT 5 03108 8 8318 EN BB jj WW SR HIH v4 p d Add 1 Shi
19. Standard Manual 04 2011 Quantity N N ANN Quantity JN NN 53 A1 S S NY 600 DUAL FUEL CONTROL PANEL SX Spirax UK Standard Assy No 060RD324SX Assy No 060RD324UK Description PANEL D F Description PANEL D F Part No 14808 15087 11596 11597 11737 10496 11869 11935 14806 13380 14332 11904 14381 14345 14215 14333 14334 14335 14460 10448 11526 11587 13356 14712 13562 12468 13381 11962 15111 12254 12016 Part No 14335 14334 11526 11904 14333 11737 14332 14806 14381 12468 14808 14460 10496 11869 14345 15087 10448 11587 11596 13356 14712 14215 12854 12855 11597 13381 13380 10525 12016 11962 11935 10507 Description LABEL RECOMMENDED WATER MCB 2 TYPE D 6KA RELAY MINIATURE 240V RELAY BASE MINIATURE 4P CONTACT AUX CBA 10 FRONT CONTACTOR Cl 9 220 240V RELAY LC3 LED 240V SWITCH ROCKER GREEN MCB 1P 2A TYPE D 6KA ALARM AUDIBLE CONTINUOUS LAMP IND RED 140 006 BASE LC RELAY 11 PIN DIN TRANSFORMER 500VA SIEMEN PUSH BUTTON BLACK PRESSURETROL 4 12BAR LAMP IND AMBER 140 007 LAMP IND GREEN 140 009 TOP COVER DANFOSS KPI36 SWITCH SELECTOR BODY SWITCH ISOLATOR 25AMP SWITCH ROCKER AMBER SWITCH ROCKER BLACK RELAY MINIATURE 24V SHAFT EXT 330mm OT HAND FUSEHOLDER 3 POLE 10x38 FACIA PANEL FR SERIES ALARM AUDIBLE PULSATING CIRCUIT BREAKER 6 3 10
20. and cooled Service Inspection of welded joints The frequency of the SAFed requirement for in service inspection of the main welded joints of the boiler is calculated by the number of cycles since the last inspection Boilers running twenty four hours a day require the shell and furnace end plate welds to be inspected at five year intervals and the longitudinal seam every ten years Boilers that are continually heated and cooled require more frequent inspection During manufacture the major longitudinal and circumferential weld seams are subject to non destructive testing by X ray and or Ultrasonic testing The boiler construction standard BS 2790 1992 class 1 specifies a minimum level of testing in order to reduce down time during testing RBC boilers are fitted with removable cladding strips located above the main shell horizontal and circumferential weld seams RBC Standard Manual 04 2011 Fulton 3 6 1 Practical Considerations continued The purpose of the in service weld inspections is to check for A Buried defects during manufacture that are outside acceptable limits Because the boiler was 100 tested during manufacture none should be found and upon proof of 100 manufacture testing these tests may be waived at the discretion of the competent person Cracks propagating from the region of the toe of the fillet weld on the shell to the tube plate weld resulting from fatigue or corrosion fatigue cracking These
21. any initial over tightening will cause the gasket to become hardened and embrittled leading to cracks and eventual failure 4 5 2 Fitting Instructions Blowdown the boiler completely see Operation Section 3 8 and examine all inspection holes in the boiler If any leakage is evident proceed as follows a Disassemble the crab s and cover plate and remove the inspection hole assembly Remove the old gasket and thoroughly clean the mating faces of the cover plate and boiler ring Place the new Topog E gasket on the cover plate ensure the gasket is the correct size and is seating flat against the plate Do not use any grease lubricant or adhesive If the new gasket is not seated properly before the plate is tightened the gasket may be pinched causing a failure when the pressure builds up Position the cover plate the boiler ring ensuring that the plate is correctly centred An off centre cover plate can concentrate forces on the gasket and cut it in two The cover plate may also drag on the boiler hole ring and fail to seal as the pressure rises Set the crab s and hand tighten the securing nut s sufficiently to provide a snug fit Tighten the nuts a further quarter of a turn using a spanner DO NOT OVERTIGHTEN Note Ensure the gasket is aligned correctly so that only the extreme edges are exposed to water treatment or oxygen attack If the gasket is misaligned overtightening to seal a leak will not prevent subsequent
22. be drained through an approved Blowdown Vessel A WARNING Do not change the boiler fuel without consulting the boiler manufacturer A WARNING Non approved modifications can cause injury and damage Contact your Fulton dealer before modifying the boiler A WARNING Lifting Equipment Make sure that lifting equipment complies with all local regulations and is suitable for the job You can be injured if you use faulty lifting equipment Make sure the lifting equipment is in good condition A WARNING Operating the boiler beyond its design limits can damage the boiler it can also be dangerous Do not operate the boiler outside its limits Do not try to up grade the boiler performance by unapproved modifications A WARNING DANGER FROM HOT SURFACES Steam Boilers have high temperature surfaces that if touched mav cause serious burns Onlv competent and qualified personnel should work or in the locality of a steam boiler and ancillarv equipment Alwavs ensure the working area and floor are clear of potential hazards work slowlv and methodicallv CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants are NOT SUPPLIED by Fulton It is the responsibility of the operator to ensure adequate supplies of chemical are available at all times including commissioning Costly repairs could be required should the plant operate without chemicals or the wrong dosag
23. cracks would not be there after manufacture but can develop in service they are caused by stress due to a combination of pressure loads differential expansion local temperature gradients oxygen impurities in the boiler water steam and inadequate pH water chemistry control Differential thermal expansion and local temperature gradients all result from continuous pressure temperature cycling and heating from cold too quickly Water treatment and in particular oxygen corrosion are covered in section 2 5 The importance of correct water treatment cannot be over emphasized To achieve long trouble free boiler life 1 2 3 Maintain the boiler at working pressure as long as possible When heating from cold do so slowly Maintain water treatment within the prescribed limits at all times 3 6 2 Starting Procedure Note When starting from cold section 3 6 1 must be read and understood if in doubt consult Fulton a b d Fill the boiler as described Section 3 5 Ensure the main steam valve is Shut Open all the valves in the gas train oil supply It is assumed that the fuel supply lines have been purged prior to attempting to start the boiler burner Turn the Pump Only Off Pump amp Burner On Switch to the Pump amp Burner On position Switch the burner mounted Burner On Off Reset Switch to the On position The 2nd Low Water and High Pressure Alarm Reset switches will illum
24. e 6 monthly or before if the feed pump has difficulty in maintaining the boiler water level To reduce the problems of possible disperser blockage chemical dosage should always be applied as a slug into the feed water pipe rather than into the feed tank By chemical slug method precipitation of solids only takes place from the water either side and mixed with the dose By dosing the feed tank all of the feed water becomes saturated with chemical causing all of the feed water entering the boiler to release precipitates sludge The exceptions are Sulphite compounds used for oxygen scavenging which can be dosed directly into the feed water tank Feed Water Mounting Flange Disperser Holes WO m OG D D D 0 OO gsx DO b ARAS 1 1 Feed Water Valve d FIG 26 FEED WATER DISPERSER RBC Standard Manual 04 2011 44 l 4 4 9 WATER LEVEL PROBE REPLACEMENT A CAUTION Ensure the new probe is cut to the same length as the probe being replaced 4 9 1 Standard Probes Brass The probe is supplied in a standard length and should be cut to the length required the length of the probe being replaced ensuring measurements are taken from the underside of the probe hexagonal nut remove any burrs caused by cutting 4 9 2 High Integrity Probes Stainless Steel The probe is supplied in two parts the head and the tip The tip should be screwed onto the head aligning the slot in the top
25. final oil connections to the oil pump c Fit isolating valves to the pump d Ensure that the supply pipe work is sized to cause a minimum pressure drop FIG 10 OIL BURNER INSTALLATION installation will change with the type of burner fitted RBC Standard Manual 04 2011 FIG 10A DUAL FUEL BURNER INSTALLATION installation will change with the type of burner fitted 2 12 ELECTRICAL REQUIREMENTS N CAUTION Anv electrical work should be undertaken bv a qualified electrician to current local regulations The boiler wiring diagram is located on the inside of the boiler control panel A 3 phase neutral and earth isolated supplv is required this should be connected to the supplv terminals of the main isolator in the boiler control panel Details of power ratings to be provided at time of order RBC Standard Manual 04 2011 Fulton 2 2 13 FRONT ACCESS DOOR INSULATION A WARNING When handling ceramic fibre always follow the local regulations regarding such materials including the use of breathing apparatus suitable body protection and protective gloves The front access door is lined with end on fibre leaving an air between the fibre and the boiler tube face plate The face of the boiler front tube plate is also insulated with end on ceramic fibre the insulation is positioned around the perimeter of the shell and over the area of tube plate above the water level The insulation is glued in
26. leakage at a later date 39 RBC Standard Manual 04 2011 Fulton 4 5 2 Fitting Instructions continued d Gradually warm up the boiler allowing steam pressure to make the seal If the gasket leaks during pressure build up tighten the securing nut s sufficiently only to stop the leakage It is important to keep the nuts correctly tightened thereafter this prevents the vacuum developed by cooling on shutdown from feeding and draining the boiler Note New gaskets fitted to inspection holes located along the bottom of the boiler are more difficult to insta without leaking Small particles of scale or sand tend to run down on the mating surfaces after cleaning but prior to assembling This condition is likely to have occurred if excess tightening is required to stop a leak before warming the boiler In this event the best course of action is to drain the boiler and repeat the gasket fitting procedure Failure to do so will severely reduce the life of the gasket e Clean and inspect each water gauge sight glass If any water leakage is evident renew the sight glass gasket HAND HOLE COVER PLATE GASKET SECURING NUT FIG 22 INSPECTION HOLE ASSEMBLY COVER PLATE AND DO NOT OVER COMPRESS COVER PLATE GASKET IN PLACE GASKET AS SHOWN NOT IN CENTRE FIG 23 FITTING ANEW TOPOG E GASKET RBC Standard Manual 04 2011 40 4 6 Fulton STEAM PRESSURE SWITCH ADJUSTMENT Pressure Gauge High Limit Pressure Switch High L
27. materials including the use of breathing apparatus suitable body protection and protective gloves The front access door is held in position by four swivel bolts A fitted with M48 hexagon nuts B The hinge side is secured by a parallel hinge system allowing the door to move away from the front face of the boiler when turning the hinge nuts B anticlockwise but still secures the door to the hinge pin The swivel bolts A on the latching side can be moved out of their securing slots once the nuts are undone In order to seal the door fully around the circumference it is important to ensure the door is parallel to the front sealing face of the boiler before finally tightening the securing nuts to effect a seal When opening and closing the door always slacken and then tighten all four nuts B not just the two on the latching side The door seal utilises a 25 x 35mm square section glass rope which is glued into an angle section welded into the perimeter of the door Over a period of time the glass rope will loose its ability to deform sufficiently to take up the irregularities between the door and sealing faces which may result in a gas leak if leakage occurs the boiler should be shut down and the seal be replaced To remove the seal locate the joint usually at the six position Prise out one end and using a chisel or similar to break the glued joint pull out the remainder of the seal B Latching side Para
28. of the tip with the hole in the screwed shaft of the head Located the pin provided into the slot hole and secure with the lock nut Using the measurement from the old probe cut the new probe to length and de burr Ensure both measurements are taken from the underside of the hex nut on the probe head Ensure measurements are taken from the Align the hole in the probe head with underside of the hex nut on the probe head the bottom of the slot in the probe tip Hold the probe head secure whilst fitting the probe tip Locknut Locate the pin in the hole slot and secure with the locknut FIG 27 HIGH INTEGRITY WATER LEVEL PROBE 45 RBC Standard Manual 04 2011 Fulton 5 7 GENERAL DATA SECTION 5 Dimensions given are approximate and must not be used for installation pipework 5 1 BOILER SPECIFICATIONS Model RBC 600 750 1000 1250 1500 1850 2100 2500 3000 Steam output kg h F amp A 100 C 957 1197 Heat output kW 600 750 Max Operating pressure 10 34 10 34 Water content litre 1350 1450 Weight empty tonne ex burner 4 31 4 71 Approximate fuel usage Light diesel oil 1 Natural gas m3 h Connections DN All flanges to BS4504 PN16 A2 unless otherwise stated Steam outlet PN16 65 65 100 Safety valve outlet PN16 40 40 50 Boiler blowdown outlet PN16 25 26 32 Feed water pump inlet BSP 20 25 Feed water pump inlet PN16 32 Sight glass blowdown B
29. out by Corgi Registered engineers AN WARNING The importance of correct boiler water and feed water can not be over emphasized see the relevant section in this manual A WARNING DANGER FROM INCOMPLETE COMBUSTION The importance of correct burner adjustment to achieve low emissions safe clean and efficient combustion is paramount Poor combustion where un burnt gas forms carbon monoxide is both a health hazard and the potential risk to the boiler from overheating caused by re burning of the un burnt gas in the secondary flue passes CAUTION Obey all laws and local regulations which affect you and your boiler CAUTION LOW FEED WATER TEMPERATURE Low feed water temperature can result in thermal shock to the boiler pressure vessel Return the maximum amount of condensate and if necessary pre heat the feed water If in doubt consult FBW AN CAUTION HYDRAULIC TEST RISK OF BRITTLE FRACTURE Hydraulic testing requires specialist equipment and is nor mally only required by engineering surveyors inspec tors The material the boiler is manufactured from has not been impact tested as it is not a requirement of BS2790 boiler construction standard In order to ensure the mate rial pres sure vessel does not suffer from brittle fracture hydraulic testing should not be carried out below 7 C AN WARNING Only qualified persons should be allowed to operate and maintain the boiler and its equipment Boilers should always
30. reset the 2nd Low Water Alarm The burner should start and the pump restore the water level to normal and stop Note This procedure requires a longer attendance time by the boiler house operator but reduces the pressure loss to the system RBC Standard Manual 04 2011 26 Fulton AN WARNING The 2nd Low water at 30mm in the sight glass must not be changed Pump On snd Low 1st Low Water High Water N Pump Off Li H t c A qum DL Normal Working Level NWL 2nd Low Water _1st Low Water FIG 18 WATER LEVEL CONTROL DIMENSIONS Note Water levels and probe lengths should be noted on commissioning and recorded with the boiler Probe lengths are nominal and must be checked against the requirements of each individual boiler model Pump OFF Pump ON 1st Low Water 2nd Low Water High Water RB600 415 440 520 545 336 RB750 415 440 520 545 336 RB1000 415 440 520 545 336 RB1250 535 560 640 665 456 RB1500 535 560 640 665 456 RB1850 515 540 620 645 436 RB2100 515 540 620 645 436 RB2500 535 560 640 665 456 RB3000 535 560 640 665 456 Note All probe lengths are measured from the underside of the hex nut Replacement probes are supplied at a standard length and should be cut to the same length as the probe being replaced 2
31. the burner off when the desired steam pressure is reached and switching it on when steam pressure falls b High Limit Switch Should the Control Pressure Switch fail the steam pressure will raise above the preset limit causing the High Limit Switch set at least 0 5 barg higher than the Control Pressure Switch to switch off and lock out the burner A High Limit Indicator will illuminate and an alarm will sound c High Low Pressure Switch 1 Air pressure transducer for fully modulated burners switches the burner from high to low flame and vice versa 2 Provides a proportional control signal to the burner combustion control Burner Programmer Is located the burner mounted control panel Acts in conjunction with a sensing device to supervise the ignition sequence prove the flame is satisfactory and finally monitor the established flame Should any fault occur either during the ignition sequence or during normal running the programmer will immediately go to lock out and both main and pilot gas oil valves will shut to isolate the fuel lines to the burner Air Pressure Switch Gas and Dual Fuel Burners only Mounted on the burner this switch is operated by the pressure of air entering the burner through the throat of the scroll Lack of combustion air or insufficient air pressure will stop the switch completing the circuit preventing the burner from operating Gas Train Assembly Consists of pilot and mai
32. too quickly from cold When starting from cold the furnace approaches its design temperature shortly after start up whereas the tube and shell temperatures are delayed by the time taken to bring the contained water up to temperature As a result the thermal expansion is at its greatest Additionally the temperature gradient which exists between the bottom and the top of the boiler is exaggerated This can be reduced by blowing the boiler down during the heat up period In practical terms the ideal solution would be to gradually raise the temperature and pressure in the boiler progressively by firing the boiler on low fire for a few minutes and leaving it to soak e g allowing the temperatures in the boiler and water to even out by diffusion for 20 to 30 minutes blowing down the boiler firing the boiler again for a little longer and soaking for less and so on If the boiler has been fired the day before the large thermal mass in the boiler will maintain the internal temperature to a point that the boiler can be simply switched on preferably on low fire and then left to reach working temperature pressure The life expectancy of the boiler and door insulation ignoring other factors is proportional to the number of thermal mechanical cycles that the boiler undergoes from cold zero pressure to working temperature and pressure A boiler that is continually maintained at working pressure will last longer than one that is constantly heated
33. 011 4 3 Fulton SIX MONTHLY continued j Remove the rear smoke box access doors Brush through the tubes to remove deposits from the products of combustion 1 Using wire brush clean the internal surfaces of the furnace and the face of the front tube plate Pay particular attention to the tube ligaments the spaces between adjacent tubes m Inspect the tube ends for any signs of splitting or burning These are symptoms of gas reburning in the tube ends as a result of poor combustion e g carbon monoxide carry over If the tube ends exhibit these signs consult Fulton Boiler Works n Clean out the rear smoke boxes to remove the deposits brushed through from the tubes p When fitted inspect the finned tubes of the economiser for clogging or blocking clean as required IMPORTANT Ensure that the rear smoke box drain connections are clean and free from deposits This is particularly important on oil fired boilers because of the acidic nature of the condensate formed RBC Standard Manual 04 2011 36 Fulton 4 4 3 SIX MONTHLY continued 37 RBC Standard Manual 04 2011 4 3 Fulton SIX MONTHLY continued AN WARNING When handling ceramic fibre always follow the local regulations regarding such materials including the use of breathing apparatus suitable body protection and protective gloves q Examine the internal surface of the door lining for defects Small repairs may be carried out by c
34. 1 1 4 RK41 E BURNER GAS MGN2000LN M3D GASKET 25mm PN16 IBC GASKET 15mm PN16 IBC RBC Standard Manual 04 2011 Quantity Oo o On RN NO NY ON A AN AS a a a a a a Fulton RBC1850 DUAL FUEL with ECONOMIZER and MOD WATER SX Spirax UK Standard Assy No Description 185RD140ESM RBC 1850 D F ECON MODU Part No 14998 12429 14659 13826 13826 14589 11825 11824 14999 10566 14661 14915 14465 10418 14997 SA2000 SA301 15005 14181 15003 0 060RM324SX 11824 12412 12449 11786 13037 13069 13123 13209 12444 13292 12456 13016 13033 12597 13277 13294 Description GAUGE TEMP 4 0 120DEGc BURNER D F MDFL2505 M3D PROBE BODY LP20 VALVE CHECK 1 1 4 RK41 E VALVE CHECK 1 1 4 RK41 E PUMP WATER CR5 24 FLANGE 1 2 PN16 4 GASKET 15mm PN16 IBC GAUGE TEMP 4 0 300 DEGc GAUGE PRESSURE 4 250PSI PROBE PA20 PRE AMPLIFIER VALVE BALL 1 1 4 PN16 VALVE GLOBE BRONZE 1 2 PROBE BRASS 7 LONG VALVE FEEDWATER DN32 MOD CLIFTON SAMPLE COOLER PRESSURE GAUGE ASSY VALVE SAFETY DN25 40 ARI VALVE CHECK DN32 DCV2 VALVE SAFETY DN40 65 ARI PANEL D F GAS MODULATING GASKET 15mm PN16 IBC GASKET 32mm PN16 IBC SWITCH DOOR LIMIT DB4 GASKET 25mm PN16 IBC GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm GASKET 65mm PN16 IBC VALVE DN100 ANGLE PAT N GAUGE REFLEX CLIFTON 350 BRUSH TUBE 38mmSINGLE GAUGE PRESSURE 6 200PSI VALVE BLOWDOWN 32mmKBV20 PROBE TIP 1000mm LP30 PROBE BODY
35. 1 RBC Standard Manual 04 2011 3 8 Note Boiler Blowdown Drain Isolation Valve Fulton BLOWDOWN PROCEDURES In order to keep the boiler and water level gauge pipework clear and free from sludge and scale build up regular blowdown should be carried out a For non automatic blowdown systems fully open the main blowdown valve using the key provided for a minimum of 10 seconds automatic systems will blowdown at set times determined by site requirements and only need checking to ensure the amount of blowdowns performed is sufficient Shut the main blowdown valve Auto Blowdown Draining The boiler may be drained by opening the boiler blowdown isolation valve having mechanically opened the auto blowdown valve As well as removing sludge Suspended solids from the boiler a second and equally important function is to maintain the TDS totally dissolved solids level to within the required limits The amount of blowdown and hence time required is dependent on the amount of TDS in the raw water supply the percentage condensate return water treatment chemicals added and the number of hours a day operation In order to establish the required blowdown rate consult your water treatment specialist who will recommend a water treatment programme in terms of appropriate chemicals and the required blowdown rate which takes these factors into account Boiler Auto Blowdown Valve Note The boiler blowdown shown is
36. 100090853 154109 531935 00909013 SON vr OL 83448 Mal Lond ESI LITE 424 n3 11 60 RBC Standard Manual 04 2011 61 Fulton RBC Standard Manual 04 2011 Fulton 5 SPARE PARTS SECTION 6 WARNING The use of incorrect parts could be a risk to safety and seriously damage your boiler Replacement Safety Valves To comply fully with safety regulations it is essential that the correct safety valves are used If in any doubt contact Fulton Boiler Works Great Britain Ltd Sales and Service Department for assistance When ordering replacement or spare parts ensure you provide all the details given in the parts lists together with the following Boiler number Boiler type Wiring Diagram No and Boiler Voltage Commissioning Date and Engineer To locate the correct spare part Always check your boiler model against the models named in the parts lists A WARNING The type size and lift pressure safety valve fitted to a boiler is specific to that boiler When ordering spare safety valves it is important that as well as the information requested above the following additional information is given Boiler design pressure given on the boiler data plate Make and type e g fig no of safety valve fitted RBC Standard Manual 04 2011 62 Fulton 6 RBC600 DUAL FUEL BOILER SX Spirax UK Standard Assy No 060RD140SX Assy No 060RD140UK 63 Description RBC600 DUA
37. 1121135 SVD YINUNE ZVY DA ld L 13123135 NO YINYNG iV ON Td Nid 9 40 X 1 MOT 15 1 9 STVNIW JL N33M138 3HIM SAV T38 13431 XVUldS ONISN dl AJM LM7 9 8S SIVNINHIL N33M138 3HIM SAV138 13431 21 ONISN dl 4 000090843 DNIMV40 OL 43438 NOILINYLSNI NOILVANILNOD LINJAD 404 1 SALON NI NI d ajo ch 8315008 x x x n B B zn E E E J3Nung 20 5 je 1 LE a B Sie 831108 5 cu ne 0 A J 6 42 AJ m C 8 IM z mi x YN Se m ie z dd 2 20 601 af 22 lt m 2 a 2 o 9 FTI L fe 22 22 xr LO w RBC Standard Manual 04 2011 53 Fulton continued 3 5 4 WIRING DIAGRAMS INSSI 1629656 YE EE 5 831104 01 CIANWIWY DNRIIM ON NadO ATIVWYON 343M 54015 AJNI YIWI 7 INSSI STVNINUAL 331108 01 GAGNWAWY SZ ML YIHLONY 2 ML 80201 2 INSSI L000 900 v mas 54311048 1304 110 Sv5 304 oN DNIMVUQ ALVG 03323H2 NMVUQ SNOIL23NNO2 831108 1WIIHAL PHT aD SOM eg E TANVd JLOWSY SWd 2 310N 604042 INSSI JLON 335 2 431108 JLON 335 8 841104 V 431108 Junivd YILVM M01 Puz Jun iv UILVM JWV H MO1Puz Junivd UJILVM DNILS31 WOU M01 Puz DNILS3I SWd WOU4 1104 AlddNS Ae
38. 17 13334 13295 13069 12456 12449 11608 13276 11786 060RX324UK 13424 13141 12444 14819 14465 11824 13123 10423 5 2000 SA3010 13080 13075 13849 14290 Description LAMP IND AMBER 140 007 SHAFT EXT 180mm OT HAND FACIA PANEL FR SERIES LAMP BULB NEON AC16 MCB 10A 1 POLE SWITCH CA10A21260E UK PUSH BUTTON AC16 SWITCH CG8 A210620E C W SWITCH HANDLE 65 RED RELAY LC3 LED 240V RELAY BASE MINIATURE 4P SWITCH ON OFF BLACK RELAY MINIATURE 240V BELL 4 230vac MOFLASH CIRCUIT BREAKER 6 3 10A BASE LC RELAY 11 PIN DIN CONTACTOR LC1 D09U7 240V SWITCH ISOLATOR 25AMP Description FACIA PANEL FR SERIES BASE LC RELAY 11 PIN DIN SHAFT EXT 180mm OT HAND MCB 10A 1 POLE CONTACTOR LC1 D09M7 220V RELAY MINIATURE 240V SWITCH ROCKER BLACK LAMP IND RED 140 006 BELL 4 230vac MOFLASH SWITCH HANDLE IP65 RED CIRCUIT BREAKER 6 3 10A SWITCH ISOLATOR 25AMP LAMP IND AMBER 140 007 LAMP IND GREEN 140 009 SWITCH ROCKER GREEN Description RB BRUSH TUBE 32mmSINGLE GASKET HIH 7 x 5 3 4 SCREW GRUB M10x10mm RB BRUSH HANDLE 2300mm FACIA FULTON FR HOR 3mm GAUGE PRESSURE 6 200PSI SWITCH DOOR LIMIT DB4 VALVE CHECK 1 41 5 VALVE STOP FLANGED DN25 GASKET 25mm PN16 IBC PANEL GAS 60 180HP AOTC LABEL RB REGISTRATION VALVE BLOWDOWN 25mmKBV20 GAUGE REFLEX CLIFTON 350 VALVE SAFETY DN25 11 2 VALVE GLOBE BRONZE 1 2 GASKET 15mm PN16 IBC GASKET 65mm PN16 IBC PROBE BRASS 36 LONG CLIFTON SAMPLE COOLER RB PRESSURE
39. 200PSI 1 12597 PROBE BODY LP30 HIGH 2 12671 BURNER GAS 860LN T3D 1 11786 GASKET 25mm PN16 IBC 11 15276 VALVE STOP FLANGED DN25 1 13291 RB BRUSH TUBE 32mmSINGLE 1 13295 RB BRUSH HANDLE 2300mm 1 13075 VALVE DN65 ANGLE PATTERN 1 13123 GASKET 65mm PN16 IBC 2 13037 GASKET 100mm PN16 IBC 2 13069 FACIA FULTON FR HOR 3mm 1 14465 VALVE GLOBE BRONZE 1 2 2 10423 PROBE BRASS 36 LONG 2 15001 VALVE SAFETY DN25 40 ARI 1 13141 VALVE BLOWDOWN 25mmKBV20 1 Assy No Description Part No Description Quantity 060RG140UK RBC600 GAS BOILER SA3010 PRESSURE GAUGE ASSY 1 14288 PUMP WATER CR1 23 1 11786 GASKET 25mm PN16 IBC 11 SA2000 CLIFTON SAMPLE COOLER 1 060RX324UK PANEL GAS 60 180HP 1 13069 FACIA FULTON FR HOR 3mm 1 19075 VALVE DN65 ANGLE PATTERN 1 13291 BRUSH TUBE 32mm SINGLE 1 13295 BRUSH HANDLE 2300 1 12456 GAUGE PRESSURE 6 200PSI 1 11608 VALVE CHECK 1 RK41 E S 1 13276 VALVE STOP FLANGED DN25 1 12449 SWITCH DOOR LIMIT DB4 1 15097 GASKET 100mm PN16 IBC 2 13141 VALVE BLOWDOWN 25mmKBV20 1 11824 GASKET 15mm PN16 IBC 3 13123 GASKET 65mm PN16 IBC 2 12671 BURNER GAS 860LN T3D 1 14465 VALVE GLOBE BRONZE 1 2 2 15001 VALVE SAFETY DN25 40 ARI 1 10423 PROBE BRASS 36 LONG 4 Assy No Description Part No Description Quantity 060RH400UK RB0600 750 DOOR ASSEMBLY SA3000 SPY GLASS ASSEMBLY 1 65 RBC Standard Manual 04 2011 600 GAS BOILER ANCILLARY SKID UK Standard Assy No Description Part No Description Quantity 060
40. 3 LED 240V Description SHAFT EXT 330mm OT HAND ALARM AUDIBLE PULSATING ALARM AUDIBLE CONTINUOUS FUSE 2A KLIPPON 20x5mm LAMP IND GREEN 140 009 SWITCH ROCKER AMBER PRESSURETROL 4 12BAR LAMP IND AMBER 140 007 MCB 2 TYPE D 6KA MCB 1P 2A TYPE D 6KA LAMP IND RED 140 006 PUSH BUTTON BLACK CIRCUIT BREAKER 6 3 10A SWITCH ROCKER GREEN CONTACTOR BLOCK N OPEN SWITCH ROCKER BLACK SWITCH SELECTOR BODY CONTACTOR 9 220 240V RELAY BASE MINIATURE 4P FUSE HOLDER 3 POLE 10x38 SWITCH ISOLATOR 25AMP SWITCH HANDLE IP65 RED BASE LC RELAY 11 PIN DIN LABEL RECOMMENDED WATER FACIA PANEL FR SERIES RELAY MINIATURE 240V RELAY MINIATURE 24V TOP COVER DANFOSS 6 TRANSFORMER 250VA SIEMEN RELAY LC3 LED 240V CONTACT AUX CBA 10 FRONT RBC Standard Manual 04 2011 Quantity Qu Ohhh Ua N Q POO NY WO WO A A AQ GW NO N tity RBC 600 750 SERVICE KIT Assy 060SR100UK Description SERVICE KIT Description GASKET 100mm PN16 IBC GASKET HIH 7 x 5 x 3 4 VALVE BALL 1 2 SPECIAL RB EYE GLASS 53mmx 3mm GLASS REFLEX B7 CLIFTON GASKET 15mm PN16 IBC GASKET 25mm PN16 IBC GASKET REFLEX 7 RB BRUSH TUBE 32mmSINGLE GASKET MAN H 305x400x25 GASKET 65mm PN16 IBC VALVE BALL 1 4 SPECIAL BELT G28017X FOR NUWAY RBC Standard Manual 04 2011 Quantity 2 70 RBC750 DUAL FUEL SX
41. 3474 310818 sel 94 EH T 03111991 4 ld m Ld 3 did Laid Ll AHNA El 179 x MOT 4 1 r E ZE u EL UT L I LL Gab 31405 dil v L 131114419 xlv H Jd Anh ELI dli D 9 14 EJHI 504 4015 5101439 HJ LIm S000 CH RBC Standard Manual 04 2011 FUSED TERMINAL FOR CONTINUATION INSTRUCTION REFER TO DRA WING ERBGp DAGI 0 3 001 PANEL 4 LI LI ka wa E C Lal i Cr kI 4 Lei a i IL La 50 Fulton 5 4 WIRING DIAGRAMS continued G ANSSI 000 90943 mM 1 0 5831108 110 404 oN 31W0 GHAQOHddV QOFYIJKI NM VO LIANN 1041807 HINHAQ urejna 38919 uon TINVd 000 2834 009288 H31 VM MOT ASE 079 SIVNINHIL N33M138 FYIM SAV 138 13431 XV8ldS ONISN dl LMI 9 8S STIVNINYSL N334138 JYIM SAV 138 13431 IT DNISN d 2 ON ld L A 0114 Nid 9 YO 7 X 000090883 01 44444 NOILINYLSNI NOILVANILNO 11132413 404 1 CAM SALON 2 NI A B DUES 1 81 ELL gt lt x dr 59 ES je J E dE BH me T ES EC 20 __ sien k s c S m 6 5 here sf Bs BRO o
42. 37 13069 13036 13303 13277 13293 13296 13826 15004 SA3010 15151 SA2000 Part No 13036 12992 13293 13274 13277 15151 SA2000 13037 13069 10422 14465 14589 12456 13826 15004 12449 11786 11824 13296 13303 060RO324UK SA3010 12413 12412 Fulton RBC3000 OIL BOILER SX Spirax UK Standard Description VALVE GLOBE BRONZE 1 2 PROBE BRASS 22 LONG PROBE BODY LP30 HIGH GASKET 32mm PN16 IBC GASKET 40mm PN16 IBC SWITCH DOOR LIMIT DB4 GAUGE PRESSURE 6 200PSI GASKET 125mm PN16 IBC PANEL OIL 75 180 AOTC GASKET 15mm PN16 IBC GASKET 25mm PN16 IBC VALVE DN125 ANGLE PAT N PUMP WATER CR5 24 PROBE TIP 1000mm LP30 GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm GASKET 80mm PN16 IBC VALVE BLOWDOWN 40mmKBV20 VALVE STOP FLANGED DN32 BRUSH TUBE 44mmSINGLE BRUSH HANDLE 3250mm VALVE CHECK 1 1 4 RK41 E VALVE SAFETY DN50 80 ARI PRESSURE GAUGE ASSY BURNER OIL NOL125 41 T3L CLIFTON SAMPLE COOLER Description GASKET 80mm PN16 IBC GASKET 125mm PN16 IBC BRUSH TUBE 44mmSINGLE VALVE DN125 ANGLE PAT N VALVE STOP FLANGED DN32 BURNER OIL NOL125 41 T3L CLIFTON SAMPLE COOLER GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm PROBE BRASS 22 LONG VALVE GLOBE BRONZE 1 2 PUMP WATER CR5 24 GAUGE PRESSURE 6 200PSI VALVE CHECK 1 1 4 RK41 E VALVE SAFETY DN50 80 ARI SWITCH DOOR LIMIT DB4 GASKET 25mm PN16 IBC GASKET 15mm PN16 IBC BRUSH HANDLE 3250mm VALVE BLOWDOWN 40mmKBV20 PANEL OIL 60 180HP AOTC PRESSURE GAUGE ASSY GASKET 40
43. 4 14784 13826 14661 SA2000 12456 14465 12597 12412 14820 13069 14679 13033 13016 13277 19292 13123 13294 13209 Part No 14679 10423 SA3010 14465 SA2000 12449 11786 11824 14291 13277 12597 13292 12456 1500 5340 13294 12412 O60RX324SX 13826 15002 13209 13037 19122 13069 13033 13016 Description PROBE BRASS 7 LONG GASKET 15mm PN16 IBC PRESSURE GAUGE ASSY GASKET 25mm PN16 IBC SWITCH DOOR LIMIT DB4 GASKET 100mm PN16 IBC PANEL D F GAS MODULATING PROBE BODY LP20 PUMP WATER CR3 29 GAUGE REFLEX CLIFTON 350 VALVE FEEDWATER DN40 VALVE CHECK 1 1 4 RK41 E PROBE PA20 PRE AMPLIFIER CLIFTON SAMPLE COOLER GAUGE PRESSURE 6 200PSI VALVE GLOBE BRONZE 1 2 PROBE BODY LP30 HIGH GASKET 32mm PN16 IBC VALVE SAFETY DN32 11 2 FACIA FULTON FR HOR 3mm BURNER GAS MGN2000LN T3D PROBE TIP 1000mm LP30 VALVE BLOWDOWN 32mmKBV20 VALVE STOP FLANGED DN32 BRUSH TUBE 38mmSINGLE GASKET 65mm PN16 IBC BRUSH HANDLE 2950mm VALVE DN100 ANGLE PAT N Description BURNER GAS MGN2000LN T3D PROBE BRASS 36 LONG PRESSURE GAUGE ASSY VALVE GLOBE BRONZE 1 2 CLIFTON SAMPLE COOLER SWITCH DOOR LIMIT DB4 GASKET 25mm PN16 IBC GASKET 15mm PN16 IBC PUMP WATER CR3 25 VALVE STOP FLANGED DN32 PROBE BODY LP30 HIGH BRUSH TUBE 38mmSINGLE GAUGE PRESSURE 6 200PSI INSULATED SHELL RB1500 BRUSH HANDLE 2950mm GASKET 32mm PN16 IBC PANEL GAS 75 180 AOTC VALVE CHECK 1 1 4 RK41 E VALVE SAFETY DN32 50 ARI VALVE DN100 A
44. 400 600 GAS BOILER 13080 GASKET MAN H 305x400x25 13075 VALVE DN65 ANGLE PATTERN 13141 VALVE BLOWDOWN 25mmKBV20 13123 GASKET 65mm PN16 IBC 13069 FACIA FULTON FR HOR 3mm SA3010 PRESSURE GAUGE ASSY 14819 VALVE SAFETY DN25 11 2 1 1 1 2 1 1 1 SA2000 CLIFTON SAMPLE COOLER 1 060RX324UK PANEL GAS 60 180HP AOTC 1 13037 GASKET 100mm PN16 IBC 2 13217 GASKET HIH 7 x 5 x 3 4 2 11161 WATER SOFTNER EL15D 1 13424 LABEL RB REGISTRATION 1 12456 GAUGE PRESSURE 6 200PSI 1 14288 PUMP WATER CR1 23 1 13276 VALVE STOP FLANGED DN25 1 19291 RB BRUSH TUBE 32mmSINGLE 1 13295 RB BRUSH HANDLE 2300mm 1 11608 VALVE CHECK 1 RK41 E S 1 11824 GASKET 15mm PN16 IBC 3 12449 SWITCH DOOR LIMIT DB4 1 12671 BURNER GAS MGN 860LN T3D 1 12444 GAUGE REFLEX CLIFTON 350 2 11786 GASKET 25mm PN16 IBC Vi 10483 DOSAGE CHEM SET SINGLE 1 10423 PROBE BRASS 36 LONG L 14465 VALVE GLOBE BRONZE 1 2 2 RBC Standard Manual 04 2011 66 600 MODULATING GAS CONTROL PANEL SX Spirax UK Standard Assy No 060RM324SX Assy No Description PANEL D F GAS MODULATING Description 060RM324UK PANEL GAS MOD 67 Description CIRCUIT BREAKER 6 3 10A CONTROLLER SPIRAX LEVEL ALARM AUDIBLE CONTINUOUS PUSH BUTTON BLACK ALARM AUDIBLE PULSATING SHAFT EXT 330mm OT HAND FUSEHOLDER 3 POLE 10x38 SWITCH SELECTOR BODY CONTROLLER LC2250 SPIRAX LAMP IND RED 140 006 SWITCH ROCKER BLACK LAMP IND GREEN 140 009 TOP COVER DANFOSS KPI36 SWITCH ISOLATOR 25AMP SWI
45. 495 A B D E F G 2 ACI o Dimensions given for Nu Way burners Other burners will vary Details of flanges will vary with specification Flue may be rear or top mounted 47 RBC Standard Manual 04 2011 Fulton 5 3 RECOMMENDED WATER CONDITIONS IMPORTANT Recommended Water Conditions for Fulton Horizontal Boilers It is very important that a strict water management program is followed to ensure trouble free boiler operation The following are recommended for feedwater and boiler water FEEDWATER water entering boiler pH Value Hardness Suspended Solids Chloride Organic Matter Oil 8 5 to 9 5 tested at room temperature less than 2 0mg kg in the form of CaCO None less than 50 less than 5mg kg None BOILER WATER water inside boiler pH Value Hardness Suspended Solids Chloride Oxygen Scavenger Sodium Sulphite or Tannin Phosphate Total Alkalinity Caustic Alkalinity Total Dissolved Solids TDS Iron Silica solved Oxygen mg kg CaCO PO4 SiO 1 Grain hardness therefore 7Oppm For practical purposes mg kg 10 5 12 0 tested at room temperature Not detectable Less than 200mg kg Less than 500mg kg 30 to 7Omg kg Less than 50mg kg the form of PO4 Less than 1000 350mg kg minimum as CaCO Less than 3500ppm Less than 1mg kg Less than 150mg kg the form of SiO Dis None Milligrams per Kilogram Calcium Carbonate
46. 5 180 AOTC PUMP WATER CR3 21 VALVE BLOWDOWN 25mmKBV20 GASKET 100mm PN16 IBC PROBE BODY LP30 HIGH CLIFTON SAMPLE COOLER GASKET 15mm 16 IBC BURNER OIL NOL 35 25 T3L FLANGE 25mm PN16 SLIP ON GASKET 25mm PN16 IBC VALVE CHECK 1 RK41 E S PROBE BRASS 36 LONG GAUGE PRESSURE 6 200PSI VALVE SAFETY DN25 40 ARI PYROLOG BLOCK 300x50x65 VALVE STOP FLANGED DN25 GASKET HIH 7 x 5 x 3 4 BRUSH TUBE 32mmSINGLE LABEL RB REGISTRATION VALVE GLOBE BRONZE 1 2 BRUSH HANDLE 2300mm Description SWITCH DOOR LIMIT DB4 GASKET 15mm PN16 IBC PUMP WATER CR3 21 VALVE GLOBE BRONZE 1 2 PROBE BRASS 36 LONG GAUGE PRESSURE 6 200PSI GASKET 65mm PN16 IBC BRUSH HANDLE 2300mm BRUSH TUBE 32mmSINGLE VALVE CHECK 1 41 5 GASKET 25mm PN16 IBC BURNER OIL NOL 35 25 T3L FACIA FULTON FR HOR 3mm PANEL OIL 60 180HP AOTC VALVE BALL 1 4 ART 45T VALVE STOP FLANGED DN25 VALVE DN65 ANGLE PATTERN VALVE BLOWDOWN 25mmKBV20 VALVE SAFETY DN25 40 ARI GASKET 100mm PN16 IBC CLIFTON SAMPLE COOLER PRESSURE GAUGE ASSY RBC Standard Manual 04 2011 Quantity N AN A W W PN NON Quantitv A A A PO BRP 74 RBC750 OIL GAS BOILER SX Spirax UK Standard Assy No 075RO324UK Assy No 075RX323UK Assy No 075RP140UK 75 Description PANEL OIL Description PANEL GAS Description RBC750 FULTON HORIZONTAL Part No 13291 132
47. 5RO 40SX RB1250 HORIZONTAL SKID10423 14465 SA2000 11824 12444 11608 13276 060 3245 SA3010 13294 12412 12449 12454 14290 14584 13292 13141 13036 14820 13123 13037 13069 12456 RBC Standard Manual 04 2011 Description GASKET HIH 7 x 5 3 4 GASKET 100mm PN16 IBC GASKET 80mm PN16 IBC VALVE STOP FLANGED DN32 GASKET 32mm PN16 IBC SWITCH DOOR LIMIT DB4 VALVE GLOBE BRONZE 1 2 VALVE DN100 ANGLE PAT N FACIA FULTON FR HOR 3mm VALVE SAFETY DN32 50 ARI BRUSH HANDLE 2950mm PRESSURE GAUGE ASSY PROBE BRASS 36 LONG BURNER GAS MGN1550LN T3D BRUSH TUBE 38mmSINGLE PUMP WATER CR3 21 VALVE BLOWDOWN 32mmKBV20 PANEL GAS 60 180HP AOTC GASKET 15mm PN16 IBC GASKET 25mm PN16 IBC GAUGE PRESSURE 6 200PSI GASKET MAN H 305x400x25 GASKET 65mm PN16 IBC CLIFTON SAMPLE COOLER VALVE CHECK 1 1 4 RK41 E Description PROBE BRASS 36 LONG VALVE GLOBE BRONZE 1 2 CLIFTON SAMPLE COOLER GASKET 15mm PN16 IBC GAUGE REFLEX CLIFTON 350 VALVE CHECK 1 41 5 VALVE STOP FLANGED DN25 PANEL GAS 75 180 AOTC RB PRESSURE GAUGE ASSY RB BRUSH HANDLE 2950mm GASKET 32mm PN16 IBC SWITCH DOOR LIMIT DB4 VALVE DN80 ANGLE PATTERN PUMP WATER CR3 21 BURNER OIL NOL 50 34 T3L RB BRUSH TUBE 38mmSINGLE VALVE BLOWDOWN 25mmKBV20 GASKET 80mm PN16 IBC VALVE SAFETY DN32 11 2 GASKET 65mm PN16 IBC GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm GAUGE PRESSURE 6 200PSI Quantity I I c RP AQ AD N Quantit
48. 69 13277 13209 13424 13123 Part 13016 13080 13037 13069 14293 12456 14465 15003 11786 SA301 13424 10423 13826 13277 13293 13296 1824 0 SA2000 13217 12449 13242 060RO324UK 12412 13209 12117 19123 12413 Part No 13033 14423 210RG240CH 14821 13826 SA2000 12456 12597 Fulton RBC2100 OIL BOILER SX Spirax UK Standard Description GASKET 25mm PN16 IBC VALVE GLOBE BRONZE 1 2 VALVE SAFETY DN40 65 ARI PROBE TIP 1000mm LP30 VALVE BALL 1 4 ART 45T VALVE BLOWDOWN 32mmKBV20 PROBE BRASS 36 LONG VALVE CHECK 1 1 4 RK41 E GASKET 100mm PN16 IBC PUMP WATER CR5 20 BURNER OIL NOL 85 38 T3L BRUSH TUBE 44mmSINGLE BRUSH HANDLE 3250mm SWITCH DOOR LIMIT DB4 PROBE BODY LP30 HIGH CLIFTON SAMPLE COOLER GASKET 15mm PN16 IBC GASKET 32mm PN16 IBC GASKET 40mm PN16 IBC GAUGE PRESSURE 6 200PSI PANEL OIL 75 180 AOTC FACIA FULTON FR HOR 3mm VALVE STOP FLANGED DN32 VALVE DN100 ANGLE PAT N LABEL RB REGISTRATION GASKET 65mm PN16 IBC Description VALVE BLOWDOWN 32mmKBV20 GASKET MAN H 305x400x25 GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm PUMP WATER CR5 20 GAUGE PRESSURE 6 200PSI VALVE GLOBE BRONZE 1 2 VALVE SAFETY DN40 65 ARI GASKET 25mm PN16 IBC PRESSURE GAUGE ASSY LABEL RB REGISTRATION PROBE BRASS 36 LONG VALVE CHECK 1 1 4 RK41 E VALVE STOP FLANGED DN32 BRUSH TUBE 44mmSINGLE BRUSH HANDLE 3250mm GASKET 15mm PN16 IBC CLIFTON SAMPLE COOLER GASKET HIH 7 x 5 3 4 SWITCH D
49. 7 11893 11824 11786 13293 12412 14363 12413 13321 13314 Part No Description EVE GLASS 53mmx 3mm GASKET USE PART 13408 GASKET H H 7 x 5 x 3 4 RB BRUSH TUBE 38mmSINGLE GASKET 100mm PN16 IBC GASKET 32mm PN16 IBC BELT G28017X FOR NUWAY GASKET 65mm PN16 IBC GASKET MAN H 305x400x25 VALVE BALL 1 4 SPECIAL GLASS REFLEX B7 CLIFTON GASKET 25mm PN16 IBC VALVE BALL 1 2 SPECIAL GASKET REFLEX 7 GASKET 15mm PN16 IBC Description GASKET MAN H 305x400x25 VALVE BALL 1 2 SPECIAL GASKET 100mm PN16 IBC VALVE BALL 1 4 SPECIAL GLASS REFLEX B7 CLIFTON GASKET 65mm PN16 IBC INSULATION GLASS FIBRE GASKET HIH 7 x 5 x 3 4 GASKET REFLEX 7 GASKET 15mm PN16 IBC GASKET 25mm PN16 IBC RB BRUSH TUBE 44mmSINGLE GASKET 32mm PN16 IBC BELT G28017X FOR NUWAY GASKET 40mm PN16 IBC GASKET USE PART 13408 RB EYE GLASS 53mmx 3mm RBC Standard Manual 04 2011 Quantity OI N QO MM Quantity N NDA O N N 92 Fulton RBC1850 DUAL FUEL SX Spirax UK Standard Assy No Description Part No Description Quantity 185RD140SX RBC1850 DUAL FUEL BOILER 13826 VALVE CHECK 1 1 4 RK41 E 1 SA3010 PRESSURE GAUGE ASSY 1 12763 BURNER D F MDFL 2505 T3D 1 13123 GASKET 65mm PN16 IBC 1 12413 GASKET 40mm PN16 IBC 1 12412 GASKET 32mm PN16 IBC 5 14293 PUMP WATER CR5 20 1 13069 FACIA FULTON FR HOR 3mm 1 060RD324SX PANEL DIE 75 180 AOTC 1 14465 VALVE GLOBE BRONZE 1 2 2
50. A CONTROLLER SPIRAX LEVEL SWITCH ON OFF BLACK SWITCH HANDLE 65 RED Description TOP COVER DANFOSS KPI36 LAMP IND GREEN 140 009 SWITCH ROCKER AMBER BASE LC RELAY 11 PIN DIN LAMP IND AMBER 140 007 CONTACT AUX CBA 10 FRONT LAMP IND RED 140 006 MCB 1P 2ATYPE D 6KA TRANSFORMER 500VA SIEMEN FACIA PANEL FR SERIES LABEL RECOMMENDED WATER SWITCH SELECTOR BODY CONTACTOR 9 220 240V RELAY LC3 LED 240V PUSH BUTTON BLACK MCB 2P 4A TYPE D 6KA SWITCH ISOLATOR 25AMP SWITCH ROCKER BLACK RELAY MINIATURE 240V RELAY MINIATURE 24V SHAFT EXT 330mm OT HAND PRESSURETROL 4 12BAR FUSE 2A KLIPPON 20x5mm FUSE CARRIER ASK1 35 RELAY BASE MINIATURE 4P ALARM AUDIBLE PULSATING ALARM AUDIBLE CONTINUOUS TERMINAL FUSE 5 AMP SWITCH HANDLE 65 RED CIRCUIT BREAKER 6 3 10A SWITCH ROCKER GREEN CONTACTOR BLOCK N OPEN RBC Standard Manual 04 2011 Quantity N N N N G a W G ANY AN COO Quantity sch A CO BR G NYO DB AOD RPE 64 Fulton 6 RBC600 GAS BOILER SX Spirax UK Standard Assy No Description Part No Description Quantity OGORG140SX RBC600 GAS BOILER 11608 VALVE CHECK 1 RK41 E S 1 060 3245 PANEL GAS 1 SA2000 CLIFTON SAMPLE COOLER 1 14288 PUMP WATER CR1 23 1 11824 GASKET 15mm PN16 IBC 3 SA3010 RB PRESSURE GAUGE ASSY 1 13033 PROBE TIP 1000mm LP30 2 12449 SWITCH DOOR LIMIT DB4 1 12456 GAUGE PRESSURE 6
51. ALVE BLOWDOWN 32mmKBV20 PANEL D F 60 180HP AOTC BRUSH HANDLE 2950mm PROBE BRASS 36 LONG PRESSURE GAUGE ASSY CLIFTON SAMPLE COOLER BURNER D F MDFL1880 T3D RBC Standard Manual 04 2011 Quantity N N A N B SN N Quantity AQ AN A Da cc 82 Assy 125RG140SX Assv No 125RG140SM 83 Description RBC1250 GAS BOILER Description RBC1250 GAS MOD WATER Fulton RBC1250 GAS BOILER SX Spirax UK Standard RBC Standard Manual 04 2011 Part No Description Quantity 10423 PROBE BRASS 36 LONG 2 13209 VALVE DN100 ANGLE PAT N 1 060RX324SX PANEL GAS 75 180 AOTC 1 SA2000 CLIFTON SAMPLE COOLER 1 14749 BURNER GAS MGN1550LN T3D 1 13069 FACIA FULTON FR HOR 3mm 1 13037 GASKET 100mm PN16 IBC 3 13016 VALVE BLOWDOWN 32mmKBV20 1 13123 GASKET 65mm PN16 IBC 1 13036 GASKET 80mm PN16 IBC 1 SA3010 PRESSURE GAUGE ASSY 1 14465 VALVE GLOBE BRONZE 1 2 2 12597 PROBE BODY LP30 HIGH 2 13033 PROBE 1000mm LP30 2 13294 BRUSH HANDLE 2950mm 1 15002 VALVE SAFETY DN32 50 ARI 1 12449 SWITCH DOOR LIMIT DB4 1 12456 GAUGE PRESSURE 6 200PSI 1 13826 VALVE CHECK 1 1 4 RK41 E 1 13826 VALVE CHECK 1 1 4 RK41 E 1 13292 BRUSH TUBE 38mmSINGLE 1 13277 VALVE STOP FLANGED DN32 1 11824 GASKET 15mm PN16 IBC 3 14290 PUMP WATER CR3 21 1 12412 GASKET 32mm PN16 IBC 8 11786 GASKET 25mm PN16 IBC 5 Part No Description Quantity 13037 GASKET 100mm PN16 I
52. ATOR 25AMP FUSEHOLDER 3 POLE 10x38 SHAFT EXT 330mm OT HAND SWITCH ROCKER BLACK RELAY BASE MINIATURE 4P PUSH BUTTON BLACK TOP COVER DANFOSS KPI36 LAMP IND RED 140 006 LAMP IND AMBER 140 007 TRANSFORMER 500VA SIEMEN PRESSURETROL 4 12BAR LAMP IND GREEN 140 009 MCB 2P 4A TYPE D 6KA RELAY LC3 LED 240V CONTACT AUX CBA 10 FRONT MCB 1 2A TYPE D 6KA RBC Standard Manual 04 2011 Quantity NANa gt 9 G N A AO OO NI Quantity DB A AQ CO CO A N CO 68 RBC600 GAS CONTROL PANEL SX Spirax UK Standard Assy No 060RX324SX Assy No 060RX324UK 69 Description PANEL GAS Description PANEL GAS Description ALARM AUDIBLE CONTINUOUS CONTROLLER SPIRAX LEVEL RELAY MINIATURE 24V PRESSURETROL 4 12BAR CIRCUIT BREAKER 6 3 10A ALARM AUDIBLE PULSATING FUSE HOLDER 3 POLE 10x38 SHAFT EXT 330mm OT HAND SWITCH ON OFF BLACK CONTACT AUX CBA 10 FRONT LABEL RECOMMENDED WATER SWITCH ROCKER AMBER SWITCH HANDLE IP65 RED FACIA PANEL FR SERIES SWITCH ROCKER GREEN RELAY BASE MINIATURE 4P SWITCH SELECTOR BODY TRANSFORMER 250VA SIEMEN PUSH BUTTON BLACK SWITCH ISOLATOR 25AMP LAMP IND RED 140 006 SWITCH ROCKER BLACK RELAY MINIATURE 240V BASE LC RELAY 11 PIN DIN MCB 1P 2ATYPE D 6KA MCB 2P 4A TYPE D 6KA LAMP IND AMBER 140 007 CONTACTOR 9 220 240V FUSE HOLDER 3P 14x51 TOP COVER DANFOSS KPI36 LAMP IND GREEN 140 009 RELAY LC
53. BC 3 14465 VALVE GLOBE BRONZE 1 2 2 13294 RB BRUSH HANDLE 2950mm 1 15002 VALVE SAFETY DN32 50 ARI 1 14181 VALVE CHECK DN32 DCV2 1 14915 VALVE BALL 1 1 4 PN16 5 14998 GAUGE TEMP 4 0 120DEGc 2 12597 PROBE BODY LP30 HIGH 2 13277 VALVE STOP FLANGED DN32 1 13292 RB BRUSH TUBE 38mmSINGLE 1 15005 VALVE SAFETY DN25 40 ARI 1 10418 PROBE BRASS 7 LONG 1 SA3010 RB PRESSURE GAUGE ASSY 1 14999 GAUGE TEMP 4 0 300 DEGc 2 13826 VALVE CHECK 1 1 4 RK41 E 1 11824 GASKET 15mm PN16 IBC 3 13033 PROBE 1000mm LP30 2 14589 PUMP WATER CR5 24 1 14659 PROBE BODY LP20 1 13069 FACIA FULTON FR HOR 3mm 1 O60RM324SX PANEL D F GAS MODULATING 1 14661 PROBE PA20 PRE AMPLIFIER 1 11786 GASKET 25mm PN16 IBC 5 13826 VALVE CHECK 1 1 4 RK41 E 1 14986 BURNER GAS MGN2000LN M3D 1 12412 GASKET 32mm PN16 IBC 6 13209 VALVE DN100 ANGLE PAT N 1 19123 GASKET 65mm PN16 IBC 1 13016 VALVE BLOWDOWN 32 20 1 SA2000 CLIFTON SAMPLE COOLER 1 12456 GAUGE PRESSURE 6 200PSI 1 10566 GAUGE PRESSURE 4 250PSI 1 14997 VALVE FEEDWATER DN32 MOD 1 12449 SWITCH DOOR LIMIT DB4 1 11824 GASKET 15mm PN16 IBC 1 12444 GAUGE REFLEX CLIFTON 350 2 Fulton RBC1250 GAS BOILER SX Spirax UK Standard Assy No Description Part No 125RG140UK RBC1250 GAS BOILER 13217 13037 13036 13277 12412 12449 14465 13209 13069 15002 13294 SA3010 10423 14749 13292 14290 13016 O60RX324UK 11824 11786 12456 13080 13123 SA2000 13826 Assy No Description Part No 12
54. BRONZE 1 2 BRUSH TUBE 44mmSINGLE SWITCH DOOR LIMIT DB4 PUMP WATER CR5 24 VALVE SAFETY DN50 80 ARI GASKET 25mm PN16 IBC COUPLING MALE STUD 1 4 VALVE DN125 ANGLE PAT N BRUSH HANDLE 3250mm VALVE BLOWDOWN 40mmKBV20 GASKET 125mm PN16 IBC PROBE TIP 1000mm LP30 PROBE BRASS 36 LONG GASKET 100mm PN16 IBC GASKET 80mm PN16 IBC FACIA FULTON FR HOR 3mm GAUGE PRESSURE 6 200PSI PROBE BODY LP30 HIGH FLANGE 32mm WELDING S O VALVE CHECK 1 1 4 RK41 E PYROLOG BLOCK 300x600x Description GASKET 25mm PN16 IBC BURNER GAS MGN3300 36T3L CLIFTON SAMPLE COOLER VALVE DN125 ANGLE PAT N VALVE STOP FLANGED DN32 GASKET 65mm PN16 IBC VALVE GLOBE BRONZE 1 2 PRESSURE GAUGE ASSY FACIA FULTON FR HOR 3mm GASKET 100mm PN16 IBC BRUSH TUBE 44mmSINGLE BRUSH HANDLE 3250mm VALVE BLOWDOWN 40mmKBV20 PROBE BRASS 36 LONG VALVE SAFETY DN50 80 ARI PUMP WATER CR5 24 PANEL GAS 60 180HP AOTC GASKET 32mm PN16 IBC GASKET 40mm PN16 IBC SWITCH DOOR LIMIT DB4 GAUGE PRESSURE 6 200PSI GASKET 125mm PN16 IBC VALVE CHECK 1 1 4 RK41 E RBC Standard Manual 04 2011 Quantity N N N N PO S EI A n Ab Quantity sch P Q SN a Assy Description 300RO140SX RBC3000 OIL BOILER Assy No Description 300RO140UK RBC3000 OIL BOILER Part No 14465 10422 12597 12412 12413 12449 12456 12992 060 245 11824 11786 13274 14589 13033 130
55. BRONZE 1 2 FACIA FULTON FR HOR 3mm GASKET 15mm PN16 IBC VALVE CHECK 1 1 4 RK41 E RB BRUSH HANDLE 3250mm VALVE BLOWDOWN 40mmKBV20 BURNER GAS MGN2800X T3D VALVE SAFETY DN50 80 ARI GASKET 25mm PN16 IBC GASKET 100mm PN16 IBC PUMP WATER CR5 22 PROBE TIP 1000mm LP30 PRESSURE GAUGE ASSY PANEL GAS 75 180 AOTC CLIFTON SAMPLE COOLER Description GASKET 40mm PN16 IBC GASKET 25mm PN16 IBC GASKET 100mm PN16 IBC BRUSH HANDLE 3250mm GASKET 32mm PN16 IBC GASKET 15mm PN16 IBC BRUSH TUBE 44mmSINGLE PANEL GAS 60 180HP AOTC GASKET 125mm PN16 IBC FACIA FULTON FR HOR 3mm PUMP WATER CR5 22 BURNER GAS MGN2800X T3D CLIFTON SAMPLE COOLER PRESSURE GAUGE ASSY VALVE STOP FLANGED DN32 VALVE BLOWDOWN 40mmKBV20 SWITCH DOOR LIMIT DB4 GAUGE PRESSURE 6 200PSI VALVE CHECK 1 1 4 RK41 E VALVE SAFETY DN50 80 ARI VALVE DN125 ANGLE PAT N VALVE GLOBE BRONZE 1 2 PROBE BRASS 36 LONG GASKET 65mm PN16 IBC RBC Standard Manual 04 2011 Quantity AQ OW DA PNY NAN Aaa LI Quantity 1 5 3 1 5 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 4 1 100 Assy Description 250RO140SX RBC2500 OIL BOILER Assy No Description 250RO140UK RBC2500 OIL BOILER 101 Part No 13274 13277 13242 14465 13826 13293 14590 15004 10423 SA3010 SA2000 11824 13296 13303 13037 11786 19125 12992 12413 12597 12412 13069 13033 12449 060 245 12456 Part 060RO324UK
56. CIA FULTON FR HOR 3mm GASKET 32mm PN16 IBC SWITCH DOOR LIMIT DB4 PANEL GAS 75 180 AOTC GASKET 15mm PN16 IBC PUMP WATER CR5 20 PROBE TIP 1000mm LP30 BURNER GAS MGN 2500 T3D VALVE CHECK 1 1 4 RK41 E GAUGE PRESSURE 6 200PSI VALVE DN100 ANGLE PAT N GASKET 25mm PN16 IBC VALVE BLOWDOWN 32mmKBV20 PRESSURE GAUGE ASSY VALVE GLOBE BRONZE 1 2 VALVE SAFETY DN40 65 ARI PROBE BRASS 36 LONG VALVE STOP FLANGED DN32 CLIFTON SAMPLE COOLER BRUSH HANDLE 3250mm PROBE BODY LP30 HIGH Description PROBE BRASS 36 LONG VALVE SAFETY DN40 65 ARI GAUGE PRESSURE 6 200PSI BURNER GAS MGN 2500 T3D BRUSH HANDLE 3250mm PRESSURE GAUGE ASSY GASKET 25mm PN16 IBC GASKET 40mm PN16 IBC VALVE CHECK 1 1 4 RK41 E PUMP WATER CR5 20 BRUSH TUBE 44mmSINGLE VALVE STOP FLANGED DN32 SWITCH DOOR LIMIT DB4 GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm VALVE BLOWDOWN 32mmKBV20 GASKET 32mm PN16 IBC VALVE DN100 ANGLE PAT N PANEL GAS 60 180HP AOTC VALVE GLOBE BRONZE 1 2 GASKET 65mm PN16 IBC GASKET 15mm PN16 IBC CLIFTON SAMPLE COOLER RBC Standard Manual 04 2011 Quantity N BR AN BR W Cc Quantity EA PO OF nad aaa Fulton RBC Standard Manual 04 2011 96 Assy 185RO140SX RBC1850 OIL BOILER Assy No 185RO140UK RBC1850 OIL BOILER Assy No 210RG140CH 97 Description Description Description RB2100 GAS BOILER Fulton RBC1850 OIL BOILER SX
57. E GAUGE PRESSURE 6 200PSI VALVE DN100 ANGLE PAT N SWITCH DOOR LIMIT DB4 GASKET 32mm PN16 IBC Quantity Il 2 l3 l3 lA lA Ya gt cA cA cA AO A A Fulton RBC1250 DUAL FUEL SX Spirax UK Standard Assy No Description 125RD140SX 1250 DUAL FUEL Assy No Description 125RD140UK 1250 DUAL FUEL 14465 060RD324SX 15002 12412 14645 Part No 12456 12449 15002 14290 13069 13209 12412 11786 13037 13292 13277 13826 14465 13016 O60RD324UK 13294 10423 SA3010 SA2000 14645 Description VALVE STOP FLANGED DN32 GASKET 80mm PN16 IBC PROBE BRASS 36 LONG PROBE TIP 1000mm LP30 VALVE CHECK 1 1 4 RK41 E PUMP WATER CR3 21 BRUSH TUBE 38mmSINGLE GASKET 100mm PN16 IBC GASKET 25mm 16 IBC PROBE BODY LP30 HIGH GASKET 15mm PN16 IBC GAUGE PRESSURE 6 200PSI VALVE DN100 ANGLE PAT N GASKET 65mm PN16 IBC VALVE BLOWDOWN 32mmKBV20 PRESSURE GAUGE ASSY SWITCH DOOR LIMIT DB4 BRUSH HANDLE 2950mm CLIFTON SAMPLE COOLER FACIA FULTON FR HOR 3mm VALVE GLOBE BRONZE 1 2 PANEL D F 75 180 AOTC VALVE SAFETY DN32 50 ARI GASKET 32mm PN16 IBC BURNER D F MDFL1880 T3D Description GAUGE PRESSURE 6 200PSI SWITCH DOOR LIMIT DB4 VALVE SAFETY DN32 50 ARI PUMP WATER CR3 21 FACIA FULTON FR HOR 3mm VALVE DN100 ANGLE PAT N GASKET 32mm PN16 IBC GASKET 25mm PN16 IBC GASKET 100mm PN16 IBC BRUSH TUBE 38mmSINGLE VALVE STOP FLANGED DN32 VALVE CHECK 1 1 4 RK41 E VALVE GLOBE BRONZE 1 2 V
58. ESSURE 6 200PSI GASKET 32mm PN16 IBC GASKET 25mm PN16 IBC GASKET 80mm PN16 IBC GASKET 15mm PN16 IBC VALVE SAFETY DN32 50 ARI VALVE CHECK 1 RK41 E S PUMP WATER CR3 21 Quantity A N N C amp O A A Quantity CQ A AO D Assy 150RD140SX 150RD140UK Description RBC1500 DUAL FUEL RBC1500 DUAL FUEL 12763 060RD324SX 13033 15002 13277 14465 12412 10423 13209 13294 13826 13069 12449 3294 14465 13016 15002 12705 13209 13826 13069 12456 060RD324UK 14291 SA2000 SA3010 12449 13277 10423 11786 13292 13485 11824 12412 Fulton RBC1500 DUAL FUEL SX Spirax UK Standard Description PROBE BODY LP30 HIGH VALVE BLOWDOWN 32mmKBV20 PUMP WATER CR3 25 GASKET 25mm PN16 IBC PRESSURE GAUGE ASSY BRUSH TUBE 38mmSINGLE GASKET 100mm PN16 IBC GASKET 15mm PN16 IBC CLIFTON SAMPLE COOLER GAUGE PRESSURE 6 200PSI BURNER D F MDFL 2505 T3D PANEL D F 75 180 AOTC PROBE TIP 1000mm LP30 VALVE SAFETY DN32 50 ARI VALVE STOP FLANGED DN32 VALVE GLOBE BRONZE 1 2 GASKET 32mm PN16 IBC PROBE BRASS 36 LONG VALVE DN100 ANGLE PAT N BRUSH HANDLE 2950mm VALVE CHECK 1 1 4 RK41 E FACIA FULTON FR HOR 3mm SWITCH DOOR LIMIT DB4 BRUSH HANDLE 2950mm VALVE GLOBE BRONZE 1 2 VALVE BLOWDOWN 32mmKBV20 VALVE SAFETY DN32 50 ARI BURNER D F MDFL 2505 T3D VALVE DN100 ANGLE PAT N VALVE CHECK 1 1 4
59. GAUGE ASSY EXHAUST HEAD 5 S S MODEL BDV 6 155L B DOWN SWITCH DOOR LIMIT DB4 PANEL GAS 60 180HP AOTC STANDARD SKID 6 60HP1 29999995 VALVE BLOWDOWN 32mmKBV20 GASKET 15mm PN16 IBC GASKET 25mm PN16 IBC TANK 3000LITRE S S TOP GAUGE REFLEX CLIFTON 350 GAUGE PRESSURE 6 200PSI VALVE SAFETY DN32 11 2 PUMP WATER CR3 25 CLIFTON SAMPLE COOLER SOLID STATE WLC L W GASKET 65mm PN16 IBC FLANGE 32mm WELDING S O GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm VALVE CHECK 1 1 4 RK41 E GASKET 32mm PN16 IBC GASKET MAN H 305x400x25 VALVE STOP FLANGED DN32 RB BRUSH TUBE 38mmSINGLE RB BRUSH HANDLE 2950mm PROBE BRASS 36 LONG VALVE DN100 ANGLE PAT N BURNER OIL NOL 60 34 T3L VALVE GLOBE BRONZE 1 2 GASKET HIH 7 x 5 x 3 4 DOSAGE CHEM SET SINGLE Description TANK 2700L INTERNALLY LABEL FULTON PLASTIC STEAM INJECTOR IN 15 DOSAGE CHEM SET SINGLE VALVE BALL 3 4 2 PIECE SOLID STATE WLC L W VALVE BALL 1 1 2 ART 45T FR1500 ANCILLARY SKID MODEL BDV 6 155L B DOWN Quantity NNa Po A A A GC G 41 41 1 00 NO a c Quantity 1 a Aa Aa Aa Aa Fulton RBC1500 1800 2100 OIL 5 ERVICE KIT SX Spirax UK Standard Assy No 150SR100UK Assy No 180SR100UK Description SERVICE KIT RB 1500 13314 Part No 13321 13217 13292 13037 12412 14363 13123 13080 12210 11895 11786 12199 11893 11824 Description SERVICE KIT 1800 2100 13080 12199 12097 12210 11895 13123 12769 1321
60. GAUGE ASSY GASKET MAN H 305x400x25 VALVE DN65 ANGLE PATTERN BURNER GAS NGL 55T3S 430 PUMP WATER CR3 21 RBC Standard Manual 04 2011 Quantity WON ON AHN WN Quantity AAA ANN A Quantity h RPE AQ A A jN N RBC1000 DUAL FUEL BOILER SX Spirax UK Standard Assy No 100RD140SX Assy No 090SR100UK 099J9310IR Description RBC1000 DUAL FUEL Description SERVICE KIT RB 900 WATER COLUMN ASSY J CON 13033 O60RD324SX 11824 13294 13276 14290 14465 13141 11608 Part No 13080 13037 13314 11895 12412 13321 11786 11893 12199 13217 13292 12210 11824 13123 11524 Description SWITCH DOOR LIMIT DB4 GASKET 65mm PN16 IBC GASKET 32mm PN16 IBC LABEL RB REGISTRATION PROBE BODY LP30 HIGH VALVE DN65 ANGLE PATTERN FACIA FULTON FR HOR 3mm CLIFTON SAMPLE COOLER ELBOW WI 1 2 PRESSURE GAUGE ASSY VALVE SAFETY DN32 50 ARI GAUGE PRESSURE 6 200PSI GASKET 100mm PN16 IBC GASKET 25mm PN16 IBC BURNER D F MDFL1880 T3D PROBE TIP 1000mm LP30 PANEL D F 75 180 AOTC GASKET 15mm PN16 IBC RB BRUSH HANDLE 2950mm VALVE STOP FLANGED DN25 PUMP WATER CR3 21 VALVE GLOBE BRONZE 1 2 VALVE BLOWDOWN 25mmKBV20 VALVE CHECK 1 RK41 E S Description GASKET MAN H 305x400x25 GASKET 100mm PN16 IBC RB EYE GLASS 53mmx 3mm GLASS REFLEX B7 CLIFTON GASKET 32mm PN16 IBC GASKET USE PART 13408
61. L FUEL Description RBC600 DUAL FUEL Part No 13295 13037 11824 11925 12456 13069 13276 060RD324SX 12449 11608 11786 14670 10423 14465 13141 13075 13123 14819 12597 SA3010 SA2000 13033 14288 Part No 13276 12456 13123 15001 11824 13291 13295 060RD324UK 13141 11786 10423 12449 13037 13069 19075 11608 SA3010 14465 SA2000 14288 14670 Description RB BRUSH HANDLE 2300mm GASKET 100mm PN16 GASKET 15mm PN16 IBC FLANGE 1 2 16 4 GAUGE PRESSURE 6 200PSI FACIA FULTON FR HOR 3mm VALVE STOP FLANGED DN25 PANEL D F 75 180 AOTC SWITCH DOOR LIMIT DB4 VALVE CHECK 1 RK41 E S GASKET 25mm PN16 IBC BURNER D F MDFL760 T3D PROBE BRASS 36 LONG VALVE GLOBE BRONZE 1 2 VALVE BLOWDOWN 25mmKBV20 VALVE DN65 ANGLE PATTERN GASKET 65mm PN16 IBC VALVE SAFETY DN25 11 2 PROBE BODY LP30 HIGH RB PRESSURE GAUGE ASSY CLIFTON SAMPLE COOLER PROBE TIP 1000mm LP30 PUMP WATER CR1 23 Description VALVE STOP FLANGED DN25 GAUGE PRESSURE 6 200PSI GASKET 65mm PN16 IBC VALVE SAFETY DN25 40 ARI GASKET 15mm PN16 IBC RB BRUSH TUBE 32mmSINGLE RB BRUSH HANDLE 2300mm PANEL D F 60 180HP AOTC VALVE BLOWDOWN 25mmKBV20 GASKET 25mm PN16 IBC PROBE BRASS 36 LONG SWITCH DOOR LIMIT DB4 GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm VALVE DN65 ANGLE PATTERN VALVE CHECK 1 41 5 RB PRESSURE GAUGE ASSY VALVE GLOBE BRONZE 1 2 CLIFTON SAMPLE COOLER PUMP WATER CR1 23 BURNER D F MDFL760 T3D RBC
62. LP30 HIGH VALVE STOP FLANGED DN32 BRUSH HANDLE 2950mm RBC Standard Manual 04 2011 Quantity ANN A PY WH UI OW a A A A AD UI A ANY x 106 Fulton 107 RBC Standard Manual 04 2011 Fulton Material amp Workmanship Warranty EP l Fl Fa m PET TE LI d LI LI Le k MTA l W I et n 7 Ta UB ET uam l Fr LI ZG a d 5 Wi 10 u uf Warranty On the Fulton Boiler Pressure Vessel Fulton Limited will repair or replace FoB factory any Fulton pressure vessel which within three 3 years of the date of delivery is found to be defective in workmanship or material provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the Manufacturer s Handbook This Warranty does not cover damage or failures that can be attributed to corrosion scale or dirt accumulation or to low water conditions This Warranty is good only in the United Kingdom of Great Britain and Northern Ireland This Warranty does not include labour or delivery charges of any kind n Fulton Limited General Warranty The Fulton general Guarantee is given in lieu of and in exclusion of any warranty expressed or implied statutory or otherwise as to the state condition performance quality or fitness of the goods Save thereunder we sh
63. MIT DB4 GAUGE PRESSURE 6 200PSI Description BASE LC RELAY 11 PIN DIN RELAY MINIATURE 240V FACIA PANEL FR SERIES SWITCH ROCKER BLACK RELAY BASE MINIATURE 4P SWITCH ROCKER AMBER PUSH BUTTON BLACK LABEL SELF MONITORING SWITCH SELECTOR BODY LAMP IND AMBER 140 007 LAMP IND GREEN 140 009 CONTACTOR CI 9 110 1 50 LAMP IND RED 140 006 CONTROLLER SPIRAX LEVEL SHAFT EXT 180mm OT HAND BELL STARKSTROM 4 110V MCB 10A 1 POLE CIRCUIT BREAKER 6 3 10A SWITCH ISOLATOR 25AMP SWITCH HANDLE IP65 RED SWITCH ROCKER GREEN RBC Standard Manual 04 2011 Quantity N G BB A AO AO Quantity A AQ AQ AN A VPN UI UI OW Fulton RBC750 OIL BOILER SX Spirax UK Standard Assy No Description 075RO140SX RBC750 OIL BOILER Assy No Description 075 1400 RBC750 OIL BOILER Part No 13080 12449 SA3010 13033 13123 13069 13075 060 245 14290 13141 13037 12597 5 2000 11824 13786 13175 11786 11608 10423 12456 15001 19719 13276 13217 13291 13424 14465 13295 Part 12449 11824 14290 14465 10423 12456 13123 13295 13291 11608 11786 13786 13069 060RO324UK 10549 13276 13075 13141 15001 13037 5 2000 SA3010 Description GASKET MAN H 305x400x25 SWITCH DOOR LIMIT DB4 PRESSURE GAUGE ASSY PROBE TIP 1000mm LP30 GASKET 65mm PN16 IBC FACIA FULTON FR HOR 3mm VALVE DN65 ANGLE PATTERN PANEL OIL 7
64. NGLE PAT N GASKET 100mm PN16 IBC GASKET 65mm PN16 IBC FACIA FULTON FR HOR 3mm PROBE TIP 1000mm LP30 VALVE BLOWDOWN 32mmKBV20 Quantity AQ ONN A WH 2 Quantity NO AQ W AN AN 88 Fulton RBC1500 GAS SX Spirax UK Standard Assy No Description Part No Description Quantity 150RG140UK RBC1500 GAS BOILER O60RX324UK PANEL GAS 60 180HP 1 13826 VALVE CHECK 1 1 4 RK41 E 1 13292 BRUSH TUBE 38mmSINGLE 1 14291 PUMP WATER CR3 25 1 10423 PROBE BRASS 36 LONG 4 11824 GASKET 15mm PN16 IBC 3 13294 RB BRUSH HANDLE 2950mm 1 13277 VALVE STOP FLANGED DN32 1 14465 VALVE GLOBE BRONZE 1 2 2 12412 GASKET 32mm PN16 IBC 6 SA3010 PRESSURE GAUGE ASSY 1 13209 VALVE DN100 ANGLE PAT N 1 SA2000 CLIFTON SAMPLE COOLER 1 14679 BURNER GAS MGN2000LN T3D 1 15002 VALVE SAFETY DN32 50 ARI 1 13069 FACIA FULTON FR HOR 3mm 1 13123 GASKET 65mm PN16 IBC 1 12449 SWITCH DOOR LIMIT DB4 1 13016 VALVE BLOWDOWN 32mmKBV20 1 12456 GAUGE PRESSURE 6 200PSI 1 19097 GASKET 100mm PN16 IBC 3 11786 GASKET 25mm PN16 IBC 5 RBC1500 OIL SX Spirax UK Standard Assy No 150RO130CH 89 Description RB1500 OIL BOILER RBC Standard Manual 04 2011 Part No 13308 13299 10564 10565 10423 14291 SA3040 10322 12449 13296 13298 13370 13069 13209 14465 13826 13016 12444 12456 14820 13295 13292 13219 13237 13277
65. No 11597 12254 11935 12016 11526 11587 11596 13381 11962 10448 15087 11737 13380 15111 14808 14638 14806 12468 10496 11869 14381 14712 14333 14345 14460 14215 14334 11904 14335 14332 Part No 12854 12016 14808 11935 12468 13380 13381 10496 10507 14460 11526 11962 11596 10448 13562 14712 11587 11597 14345 14335 14332 14333 14381 14215 14334 15087 11869 11737 14806 Description RELAY BASE MINIATURE 4P SWITCH ON OFF BLACK SWITCH ROCKER GREEN SWITCH HANDLE 65 RED SWITCH ROCKER AMBER SWITCH ROCKER BLACK RELAY MINIATURE 240V ALARM AUDIBLE PULSATING CIRCUIT BREAKER 6 3 10A SWITCH ISOLATOR 25AMP MCB 2P 4A TYPE D 6KA CONTACT AUX CBA 10 FRONT ALARM AUDIBLE CONTINUOUS CONTROLLER SPIRAX LEVEL LABEL RECOMMENDED WATER FUSE HOLDER 3P 14x51 MCB 1 2A TYPE D 6KA FACIA PANEL FR SERIES CONTACTOR 9 220 240V RELAY LC3 LED 240V TRANSFORMER 500VA SIEMEN SHAFT EXT 330mm OT HAND LAMP IND AMBER 140 007 PUSH BUTTON BLACK SWITCH SELECTOR BODY PRESSURETROL 4 12BAR LAMP IND GREEN 140 009 BASE LC RELAY 11 PIN DIN TOP COVER DANFOSS KPI36 LAMP IND RED 140 006 Description FUSE 2A KLIPPON 20x5mm SWITCH HANDLE 65 RED LABEL RECOMMENDED WATER SWITCH ROCKER GREEN FACIA PANEL FR SERIES ALARM AUDIBLE CONTINUOUS ALARM AUDIBLE PULSATING CONTACTOR 9 220 240V CONTACTOR BLOCK N OPEN SWITCH SELECTOR BODY SWITCH ROCKER AMBER CIRCUIT BREAKER 6 3 10A RELAY MINIATURE 240V SWITCH ISOL
66. ONZE 1 2 VALVE BALL 1 4 ART 45T GASKET 15mm PN16 IBC VALVE BLOWDOWN 32mmKBV20 PRESSURE GAUGE ASSY FACIA FULTON FR HOR 3mm VALVE CHECK 1 1 4 RK41 E PUMP WATER CR5 20 GASKET 100mm PN16 IBC GASKET 65mm PN16 IBC PROBE TIP 1000mm LP30 VALVE SAFETY DN40 65 ARI PANEL GAS 75 180 AOTC Description VALVE STOP FLANGED DN32 GASKET HIH 7 x 5 3 4 BRUSH HANDLE 3250mm GASKET MAN H 305x400x25 BRUSH TUBE 44mmSINGLE VALVE DN100 ANGLE PAT N GASKET 65mm PN16 IBC GASKET 40mm PN16 IBC GASKET 32mm PN16 IBC PANEL GAS 60 180HP AOTC FACIA FULTON FR HOR 3mm GASKET 15mm PN16 IBC BURNER GAS MGN2800X T3D GASKET 100mm PN16 IBC SWITCH DOOR LIMIT DB4 VALVE GLOBE BRONZE 1 2 VALVE BLOWDOWN 32mmKBV20 GAUGE PRESSURE 6 200PSI VALVE SAFETY DN40 65 ARI CLIFTON SAMPLE COOLER GASKET 25mm PN16 IBC PRESSURE GAUGE ASSY PROBE BRASS 36 LONG VALVE CHECK 1 1 4 RK41 E PUMP WATER CR5 20 RBC Standard Manual 04 2011 Quantity CQ A A A OD N N Quantity a OF A AN WO AW OI Aaa nd N 98 Assy Description 210 1405 2100 OIL BOILER Assy No Description 210RO140UK RBC2100 OIL BOILER Assy No 210RO140CX 99 Description RB2100 OIL SPIRAX CTLS Part No 11786 14465 15003 13033 10549 13016 10423 13826 13037 14293 13237 13293 13296 12449 12597 SA2000 11824 12412 12413 12456 060 245 130
67. OOR LIMIT DB4 BURNER OIL NOL 100 38T3L PANEL OIL 60 180HP AOTC GASKET 32mm PN16 IBC VALVE DN100 ANGLE PAT N FLANGE BLANK 25mm PN16 8 GASKET 65mm PN16 IBC GASKET 40mm PN16 IBC Description PROBE TIP 1000mm LP30 PIPELINE SET BCS1 1 2 RB2100 FULTON HORIZONTAL VALVE SAFETY DN40 11 2 VALVE CHECK 1 1 4 RK41 E CLIFTON SAMPLE COOLER GAUGE PRESSURE 6 200PSI PROBE BODY LP30 HIGH RBC Standard Manual 04 2011 Quantity sch A W NY ND NB Quantity OCF PY EA P NS Q Quantity 2 1 1 1 1 1 1 Assy Description 250RG140SX 2500 GAS BOILER Assy No Description 250RG140UK RBC2500 GAS BOILER Part No 12412 12456 12413 12449 12597 13293 13123 13274 13277 10423 14465 13069 11824 13826 13296 13303 14591 15004 11786 13037 14590 13033 SA3010 O60RX324SX SA2000 Part No 12413 11786 13037 13296 12412 11824 13293 060RX324UK 12992 13069 14590 14591 5 2000 SA3010 13277 13303 12449 12456 13826 15004 13274 14465 10423 13123 Fulton RBC2500 GAS BOILER SX Spirax UK Standard Description GASKET 32mm PN16 IBC GAUGE PRESSURE 6 200PSI GASKET 40mm PN16 IBC SWITCH DOOR LIMIT DB4 PROBE BODY LP30 HIGH BRUSH TUBE 44mmSINGLE GASKET 65mm PN16 IBC VALVE DN125 ANGLE PAT N VALVE STOP FLANGED DN32 PROBE BRASS 36 LONG VALVE GLOBE
68. RB BRUSH TUBE 38mmSINGLE 1 12449 SWITCH DOOR LIMIT DB4 1 14584 BURNER OIL NOL 50 34 T3L 1 13294 RB BRUSH HANDLE 2950mm 1 12444 GAUGE REFLEX CLIFTON 350 2 SA3010 RB PRESSURE GAUGE ASSY 1 13037 GASKET 100mm PN16 IBC 2 SA2000 CLIFTON SAMPLE COOLER 1 14290 PUMP WATER CR3 21 1 14820 VALVE SAFETY DN32 11 2 1 12456 GAUGE PRESSURE 6 200PSI 1 11786 GASKET 25mm PN16 IBC 1 11608 VALVE CHECK 1 RK41 E S 1 3 19 11824 GASKET 15mm 16 IBC RBC Standard Manual 04 2011 Fulton RBC1000 OIL BOILER SX Spirax UK Standard Assy No Description 100RO140UK RBC1000 OIL BOILER 060RO324UK 11824 14465 11608 14290 13294 12412 13037 SA301 13292 13075 0 SA2000 11786 14584 13276 12449 12456 13069 13123 15002 13141 RBC1200 SERVICE KIT SX Spirax UK Standard Assy No 120SR100UK Description SERVICE KIT RB 1200 Part No 13036 12412 11893 12199 12210 11895 13037 13123 13217 11824 11786 13080 13321 13292 13314 14363 Description LABEL RB REGISTRATION PROBE BRASS 36 LONG PANEL OIL 60 180HP AOTC GASKET 15mm PN16 IBC VALVE GLOBE BRONZE 1 2 VALVE CHECK 1 RK41 E S PUMP WATER CR3 21 BRUSH HANDLE 2950mm GASKET 32mm PN16 IBC GASKET 100mm PN16 IBC PRESSURE GAUGE ASSY BRUSH TUBE 38mmSINGLE VALVE DN65 ANGLE PATTERN CLIFTON SAMPLE COOLER GASKET 25mm PN16 IBC BURNER OIL NOL 50 34 T3L VALVE STOP FLANGED DN25 SWITCH DOOR LIMIT DB4 GAUGE PRESSURE 6 200PSI FACIA FULTON FR HOR 3mm GASKET
69. RI GASKET 65mm PN16 IBC VALVE CHECK 1 41 5 FACIA FULTON FR HOR 3mm BRUSH TUBE 32mmSINGLE PROBE BRASS 36 LONG VALVE BLOWDOWN 25mmKBV20 GASKET 100mm PN16 IBC PROBE TIP 1000mm LP30 GASKET H H 7 x 5 x 3 4 VALVE STOP FLANGED DN25 BRUSH HANDLE 2300mm PROBE BODY LP30 HIGH LABEL RB REGISTRATION GAUGE PRESSURE 6 200PSI BURNER GAS MGN 860LN T3D RBC Standard Manual 04 2011 Quantity 1 1 1 O G N FPF Quantity AQ BJ AO N N N PO Q a 0 72 Fulton RBC750 GAS BOILER SX Spirax UK Standard Assy No Description 075RG140UK RBC750 GAS BOILER Assy No Description 075RG321UK PANEL GAS 75 180HP AOTC 73 060RX324UK 12449 12456 Part No 11904 11596 12468 11587 11597 11526 14345 14782 14460 14333 14334 10491 14332 15111 13560 10576 13636 11962 10448 12016 11935 Description GASKET 100mm PN16 IBC VALVE BLOWDOWN 25mmKBV20 BRUSH HANDLE 2300mm VALVE STOP FLANGED DN25 VALVE DN65 ANGLE PATTERN LABEL RB REGISTRATION BURNER GAS MGN 860LN T3D GASKET HIH 7 x 5 x 3 4 BRUSH TUBE 32mmSINGLE VALVE CHECK 1 41 5 GASKET MAN H 305x400x25 FACIA FULTON FR HOR 3mm GASKET 65mm PN16 IBC PROBE BRASS 36 LONG GASKET 15mm PN16 IBC PRESSURE GAUGE ASSY VALVE GLOBE BRONZE 1 2 VALVE SAFETY DN25 40 ARI GASKET 25mm PN16 IBC PUMP WATER CR3 21 CLIFTON SAMPLE COOLER PANEL GAS SWITCH DOOR LI
70. RK41 E FACIA FULTON FR HOR 3mm GAUGE PRESSURE 6 200PSI PANEL D F 60 180HP AOTC PUMP WATER CR3 25 CLIFTON SAMPLE COOLER PRESSURE GAUGE ASSY SWITCH DOOR LIMIT DB4 VALVE STOP FLANGED DN32 PROBE BRASS 36 LONG GASKET 25mm PN16 IBC BRUSH TUBE 38mmSINGLE FLANGE 32mm SCREWED PN16 GASKET 15mm PN16 IBC GASKET 32mm PN16 IBC RBC Standard Manual 04 2011 Quantity B OE NO AN WW gt NY Aa A A A A S A 86 Fulton RBC1500 DUAL FUEL CONTROL PANEL SX Spirax UK Standard Assy No 150RD324UK Description PANEL DUAL FUEL Description Quantity SWITCH CA10A21260E SWITCH CG8 A210620E C W BELL 4 230vac MOFLASH TRANSFORMER 240V 24 50VA FACIA PANEL FR SERIES CONTROLLER SPIRAX LEVEL SWITCH ISOLATOR 25AMP LAMP IND AMBER 140 007 BASE LC RELAY 11 PIN DIN SWITCH ON OFF BLACK RELAY MINIATURE 240V SHAFT EXT 180mm OT HAND SWITCH HANDLE IP65 RED LABEL SELF MONITORING PUSH BUTTON BLACK SWITCH SELECTOR BODY MCB 10A 1 POLE RELAY LC3 LED 240V RELAY BASE MINIATURE 4P PUSH BUTTON AC16 LAMP BULB NEON AC16 CONTACTOR LC1 D09U7 240V CIRCUIT BREAKER 6 3 10A IS O O ANN AH N HW RBC1500 GAS with ECONOMIZER and MOD WATER Assy No Description Part No Description Quantity 150RG140EM RBC 1500 E M 11824 GASKET 15mm PN16 IBC 3 13294 BRUSH HANDLE 2950mm 1 14999 GAUGE TEMP 4 0 300 DEGc 2 13826 VALVE
71. SA3010 11824 13033 13292 13294 11786 19123 14290 13075 13424 13141 13037 13069 14465 Part No O60RX324UK 13037 11824 15002 11786 12412 SA2000 11608 13294 14465 13141 14797 13276 13292 10422 11774 13123 12449 14290 13980 13069 13075 13424 12456 Description SWITCH DOOR LIMIT DB4 PANEL GAS 75 180 AOTC VALVE SAFETY DN32 50 ARI GASKET 32mm PN16 IBC GAUGE PRESSURE 6 200PSI VALVE STOP FLANGED DN25 VALVE CHECK 1 RK41 E S PROBE BODY LP30 HIGH BURNER GAS MGN1550LN T3D PRESSURE GAUGE ASSY GASKET 15mm PN16 IBC PROBE TIP 1000mm LP30 RB BRUSH TUBE 38mmSINGLE RB BRUSH HANDLE 2950mm GASKET 25mm PN16 IBC GASKET 65mm PN16 IBC PUMP WATER CR3 21 VALVE DN65 ANGLE PATTERN LABEL RB REGISTRATION VALVE BLOWDOWN 25mmKBV20 GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm VALVE GLOBE BRONZE 1 2 Description PANEL GAS GASKET 100mm PN16 IBC GASKET 15mm PN16 IBC VALVE SAFETY DN32 50 ARI GASKET 25mm PN16 IBC GASKET 32mm PN16 IBC CLIFTON SAMPLE COOLER VALVE CHECK 1 RK41 E S BRUSH HANDLE 2950mm VALVE GLOBE BRONZE 1 2 VALVE BLOWDOWN 25mmKBV20 BURNER GAS MGN1550LN T3D VALVE STOP FLANGED DN25 BRUSH TUBE 38mmSINGLE PROBE BRASS 22 LONG PROBE BRASS 394mm LONG GASKET 65mm PN16 IBC SWITCH DOOR LIMIT DB4 PUMP WATER CR3 21 PROBE BRASS 430mm LONG FACIA FULTON FR HOR 3mm VALVE DN65 ANGLE PATTERN LABEL RB REGISTRATION GAUGE PRESSURE 6 200PSI RBC Standard Manual 04 2011 Quantity N
72. SP 15 19 19 TDS blowdown outlet PN16 25 25 25 Boiler water sampling PN16 15 15 15 Gas inlet natural gas 40 40 40 40 Gas inlet natural gas PN16 bo Power kW Burner fan diesel oil fired Burner fan gas fired Burner fan dual fuel Feed water pump Gas booster not fitted RBC Standard Manual 04 2011 46 Fulton 5 5 2 BOILER DIMENSIONS Note All dimensions are approximate and should not be used for installation Additional connections will be required for auxiliary steam air release and extra safety valves Clearance must be left all round the boiler for maintenance access Model RBC 600 750 1000 1250 1500 1850 2100 2500 3000 Boiler length Shell length 2145 2180 Rear gas chamber depth 250 300 Tube withdrawal 2150 2185 Door opening radius 1735 1735 Front door depth 240 240 Oil burner 865 865 Gas burner 795 795 Dual fuel burner 835 835 Safety valve to front 2090 2090 Steam outlet to front 890 890 Overall width 1960 1960 Base frame width 1700 1700 Shell diameter 1500 1500 Steam outlet to floor 2245 2245 Safety valve to floor 2205 2205 Rear flue outlet to floor 1700 1700 Top flue outlet to floor 2405 Sampling outlet to floor 1460 1460 T Flue diameter nominal 250 300 U Furnace centreline to floor 980 980 V Boiler centreline to floor 1200 1200 Feedwater pump inlet to floor 290 290 X Boiler blowdown height 300 300 Vee Flue outlet depth 152 152 Z Overall height 2495 2
73. STEAM BOILER RBC Standard Manual 04 2011 Fulton INTRODUCTION SECTION 1 1 1 GENERAL The Fulton RBC Series Steam Boiler is a conventional reverse fired three pass wet back boiler with internal economizer constructed to BS 2790 1992 The boiler is mounted on a skid frame and is equipped with control and combustion equipment according to individual specifications The control and combustion equipment can be fitted on either side of the boiler to suit the installation Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained However satisfactory performance can only be ensured if the installation recommendations operating routines and maintenance procedures detailed in this manual are adhered to The boiler is fitted with front and rear access doors to the combustion zones for cleaning and maintenance purposes Waterside access is via a manhole in the crown of the boiler while hand head holes provided in the lower boiler shell to facilitate inspection The optional economizer is a finned tube heat exchanger mounted in the rear smoke box of the boiler A standard complement of valves and mountings are fitted as follows a Main Steam Valve f Feed Water and Non return Valve b Safety Valve g Water Level and Steam Pressure Controls c Blowdown Valves h Water Sample Valve d Water Level Gauge Sets j Auxiliary Steam Valve e Steam Pressure Gauge Sy
74. Spirax UK Standard Assy No Description 075RD140SX RBC750 DUAL FUEL Assy No Description 075RD140UK RBC750 DUAL FUEL 71 Fulton Part No SA2000 14290 14465 O60RD324SX 11786 14848 12597 SA3010 11824 12449 12456 13037 13033 11608 13075 13295 10423 10549 13291 15001 13069 13141 13276 13123 Part No 060RD324UK 14290 13276 10549 SA2000 14465 11824 14848 SA3010 11608 11786 10423 15001 13291 13295 13069 13037 12405 13123 12449 13141 12456 13075 Description CLIFTON SAMPLE COOLER PUMP WATER CR3 21 VALVE GLOBE BRONZE 1 2 PANEL D F 75 180 AOTC GASKET 25mm PN16 IBC BURNER D F MDFL 1070 T3D PROBE BODY LP30 HIGH PRESSURE GAUGE ASSY GASKET 15mm PN16 IBC SWITCH DOOR LIMIT DB4 GAUGE PRESSURE 6 200PSI GASKET 100mm PN16 IBC PROBE TIP 1000mm LP30 VALVE CHECK 1 RK41 E S VALVE DN65 ANGLE PATTERN BRUSH HANDLE 2300mm PROBE BRASS 36 LONG VALVE BALL 1 4 ART 45T BRUSH TUBE 32mmSINGLE VALVE SAFETY DN25 40 ARI FACIA FULTON FR HOR 3mm VALVE BLOWDOWN 25mmKBV20 VALVE STOP FLANGED DN25 GASKET 65mm PN16 IBC Description PANEL D F 60 180HP AOTC PUMP WATER CR3 21 VALVE STOP FLANGED DN25 VALVE BALL 1 4 ART 45T CLIFTON SAMPLE COOLER VALVE GLOBE BRONZE 1 2 GASKET 15mm PN16 IBC BURNER D F MDFL 1070 T3D PRESSURE GAUGE ASSY VALVE CHECK 1 RK41 E S GASKET 25mm PN16 IBC PROBE BRASS 36 LONG VALVE SAFETY DN25 40 ARI BRUSH TUBE 32mmSINGLE BRUSH HANDLE 2300mm FACIA
75. Spirax UK Standard Part No Description 12449 SWITCH DOOR LIMIT DB4 13293 BRUSH TUBE 44mmSINGLE 13826 VALVE CHECK 1 1 4 RK41 E 14293 PUMP WATER CR5 20 12413 GASKET 40mm PN16 IBC 13296 BRUSH HANDLE 3250mm 19277 VALVE STOP FLANGED DN32 10423 PROBE BRASS 36 LONG 14465 VALVE GLOBE BRONZE 1 2 13069 FACIA FULTON FR HOR 3mm 12456 GAUGE PRESSURE 6 200PSI 13037 GASKET 100mm PN16 IBC 12412 GASKET 32mm PN16 IBC 13209 VALVE DN100 ANGLE PAT N 12597 PROBE BODY LP30 HIGH 19123 GASKET 65mm PN16 IBC 13033 PROBE TIP 1000mm LP30 19291 BURNER OIL NOL 85 38 T3L 15003 VALVE SAFETY DN40 65 ARI 13016 VALVE BLOWDOWN 32mmKBV20 11824 GASKET 15mm PN16 IBC SA3010 PRESSURE GAUGE ASSY 11786 GASKET 25mm PN16 IBC O60RO324SX PANEL OIL 75 180 AOTC SA2000 CLIFTON SAMPLE COOLER Part No Description 13826 VALVE CHECK 1 1 4 RK41 E 13277 VALVE STOP FLANGED DN32 12449 SWITCH DOOR LIMIT DB4 12456 GAUGE PRESSURE 6 200PSI 060RO324UK PANEL OIL 60 180HP AOTC 11786 GASKET 25mm PN16 IBC 13296 BRUSH HANDLE 3250mm 13209 VALVE DN100 ANGLE PAT N 12413 GASKET 40mm PN16 IBC 14293 PUMP WATER CR5 20 11824 GASKET 15mm PN16 IBC 13293 BRUSH TUBE 44mmSINGLE 12412 GASKET 32mm PN16 IBC 14465 VALVE GLOBE BRONZE 1 2 SA2000 CLIFTON SAMPLE COOLER 13237 BURNER NOL 85 38 T3L 13069 FACIA FULTON FR HOR 3mm 10423 PROBE BRASS 36 LONG 13016 VALVE BLOWDOWN 32mmKBV20 13123 GASKET 65mm PN16 IBC SA3010 PRESSURE GAUGE ASSY 13037 GASKET 100
76. Switch to the Pump On position T Vent the pump 8 Place the Pump Only Off Pump amp Burner On switch to the Pump Only position 9 The feed pump should start check the pump direction of rotation and fill the boiler to the correct working level and then switch Off Note If the 2nd Low Water and High Pressure Alarm Reset switches illuminate and the alarms sound check that the burner mounted Burner On Off Reset Switch is in the Off position and then reset both alarms by pressing the switches Note It may be necessary to vent the feed pump by bleeding air from the plug mounted in the top casting below the pump motor to pump body connection 21 RBC Standard Manual 04 2011 Fulton 3 5 1 DRAINING THE BOILER 1 A CAUTION Local Regulations State Boiler Water above 43C must not be discharged into the drainage system Ensure the boiler is cold Operators should note The boiler must be allowed to cool before the engineer starts his maintenance procedure Isolate the boiler electrics at the isolator on the Control Box door Isolate the Feed Water Tank and the Feed Water Pumps Open the Drain Valve in the boiler and the boiler air vent if fitted allowing air into the boiler Open the Blowdown Vessel Drain Valve Open all valves in the drain lines Skid Units Plant Rooms have internal drainage systems which require the same procedures Boilers with automatic blowdown systems 1 4 The boil
77. TCH HANDLE IP65 RED LAMP IND AMBER 140 007 TRANSFORMER 500VA SIEMEN DEKAFIX NUMBER 18 BASE LC RELAY 11 PIN DIN MCB 2P 4A TYPE D 6KA SWITCH ROCKER AMBER FACIA PANEL FR SERIES RELAY MINIATURE 240V CONTACT AUX CBA 10 FRONT PRESSURETROL 4 12BAR RELAY BASE MINIATURE 4P MCB 1P 2ATYPE D 6KA CONTACTOR LC1 D09U7 240V RELAY MINIATURE 24V Description ALARM AUDIBLE CONTINUOUS SWITCH ROCKER AMBER SHAFT EXT 180mm OT HAND ALARM AUDIBLE PULSATING FUSEHOLDER 3 POLE 10x38 PRESSURETROL 4 12BAR RELAY MINIATURE 240V MCB 1P 2ATYPE D 6KA BASE LC RELAY 11 PIN DIN RELAY LC3 LED 240V SWITCH ROCKER BLACK SWITCH ISOLATOR 80AMP SWITCH HANDLE IP65 RED FUSE 16AMP CARTRIDGE CONTACTOR LC1 D09U7 240V FACIA PANEL FR SERIES RELAY MINIATURE 24V RELAY BASE MINIATURE 4P TOP COVER DANFOSS KPI36 TRANSFORMER 500VA SIEMEN CIRCUIT BREAKER 6 3 10A FUSE 2 AMP CARTRIDGE MCB 2P 4A TYPE D 6KA LAMP IND GREEN 140 009 LAMP IND AMBER 140 007 LABEL SELF MONITORING CONTROLLER LC2250 SPIRAX LAMP IND RED 140 006 FUSE HOLDER 3P 14x51 PUSH BUTTON BLACK FUSE 40AMP CARTRIDGE HBC SWITCH SELECTOR BODY RBC Standard Manual 04 2011 Quantity N a ON 20 AQ N AQ VN N Quantity WAND S CQ Y GO RBC600 OIL CONTROL PANEL SX Spirax UK Standard Assy No Description 060RO324SX PANEL OIL Assy No Description 060RO324UK PANEL OIL Part
78. a Competent Person at intervals not exceeding 14 months The scope of the examination and the actual intervals between examinations is at the discretion of the competent person It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which a defect may give rise to danger Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover periodic statutory inspections For further information contact a SAFed SAFETY ASSESSMENT FEDERATION Limited Nutmeg House 60 Gainsford Street Butlers Wharf London 5 1 2NY b Health and Safety Executive local office c Your insurance company broker RBC Standard Manual 04 2011 Fulton LIST OF CONTENTS TITLE INTRODUCTION General Technical Data INSTALLATION General Siting Ventilation Flue Outlet Water Supply Blowdown Valves Main Steam Valve Safety Valve Water Gauge Set Gas Supply Oil Supply Electrical Requirements Front Access Door Insulation OPERATION General Boiler Fittings and Controls Boiler Control Panel Burner Mounted Control Panel Internal Economizer Boiler Platform Filling the Boiler Draining the Boiler Starting the Burner from Cold Daily Operating Tests UV Photo Cell Check Pump Check 1st Low Water Check 2nd Low Water Check Blowdown Procedures Boiler Blowdown Water Level Gauge Blowdown Burner Shut Down Short Term Ho
79. all be under no obligation or liability of any kind to you in regard to the goods In the case of new goods manu factured and supplied by us we will make good any defect developing therein under proper use within 12 months of delivery provided that after investigation in our sole discretion we are satisfied that the defect arose from faulty design materials or workmanship and from no other cause whatsoever Defective goods or parts must be returned to us as soon as possible after discovery of the defect Costs of carriage and of detaching and incorporating parts will be borne by you In all cases at the termination of such 12 months all liability on our part will cease No liability whatsoever is to be incurred by us in respect of gauge or sight glasses packing glands or electric motors or any goods or accessories not of our manufacture But so far as we are able we shall let you have the benefit of any guarantee or warranty given to us in respect thereof 108 RBC Standard Manual 04 2011 Fulton Fulton Limited Factory and Export Sales Broomhill Road Telephone 0117 972 3322 Bristol Sales and Service 0117 977 2563 BS4 4TU Fax 0117 972 3358 www fulton com RBC Standard Manual 04 2011
80. an automatic installation manual blowdown is also available FIG 19 MAIN BOILER BLOWDOWN Automatic Valve RBC Standard Manual 04 2011 28 5 3 8 2 Water Gauge Blowdown Blowdown the water gauge set 1 1 Open the gauge glass blowdown valve A 2 Close for approx 3 seconds the top gauge valve B 3 Open valve B 4 Close for approx 3 seconds the bot tom gauge valve C 5 Open valve C 6 Close valve A Repeat for gauge set 2 On completion of the blowdown procedure ensure that all isolation valves are open and all blow down valves are closed FIG 20 WATER GAUGE INSTALLATION Note Where a Boiler is operating continuously at steam pressure advice should be taken from a Fulton agent as to the appropriate blowdown proce dure WORKING STEAM WATER POSITION BLOWDOWN BLOWDOWN Water Level Gauge operating positions FIG 21 WATER GAUGE OPERATION 29 RBC Standard Manual 04 2011 Fulton 3 9 BURNER SHUT DOWN 3 9 1 Short Term Hours Select Off on the burner control panel switch The burner will stop firing post purge and then stop 3 9 2 Medium Term Days a b Select Off on the burner control panel switch The burner will stop firing post purge and then stop Shut the main steam valve Select pump only on the boiler control panel Note Ensure the boiler water treatment levels for dissolved oxygen are within the specified limits 3 9 3 Long Term Weeks
81. conomizer which inturn heats the feed water to temperatures that can exceed 100 C Back flow is prevented by non return valves in the feed water pipe work on the inlet and outlet of the economizer A non return valve is fitted after the boiler feed water pump to protect it from excessive temperatures The economizer is designed to reduce the boiler exhaust temperature to approximately 140 C if the temperature falls significantly below this figure condensation will occur which can lead to corrosion The economizer is fitted with inlet and outlet temperature gauges for both feed water and exhaust gas These gauges should be used to monitor the condition and performance of the economizer Note Sudden changes in temperature should be reported immediately as they could indicate a blockage of the economizer water ways or a malfunction of the modulating feed water control valve In general a 10 degree centigrade increase in feed water temperature will give an efficiency improvement of 2 Because the boiler feed water modulating control valve and the burner are both proportioned to the steam load the burner heat input and cooling water flow rate to the economizer are in balance throughout the burner firing range A 15mm spill back line with an adjustable lock shield valve is installed in the feed water pipe work in the discharge from the pump the outlet from this valve must be piped back to the feed water tank The purpose of the spill back line is
82. e of chemicals RBC Standard Manual 04 2011 Fulton LIST OF ILLUSTRATIONS TITLE RBC Series Steam Boiler Boiler Vent Safety Valve and Top Flue Flue Connection Flange Feed Water Inlet Automatic Boiler Blowdown Main Steam Valve Safety Valve Feed Water Level Gauges Gas Burner Installation Oil Burner Installation Dual Fuel Burner Installation Front Access Door Insulation General Arrangement Boiler Control Box Gas Burner Installation Boiler Control Panel Burner Control Panel Typical Boiler Platform Manual Blowdown Button Typical Flame Sensor Removal Water Level Control Dimension Main Boiler Blowdown Water Gauge Installation Water Gauge Operation Inspection Hole Assembly Fitting Inspection Hole Gasket Pressure Switch Location Door Hinge and Latch Assembly Feed Water Disperser High Integrity Water Level Probe Electrical Circuits Valve Schedule Spares RBC Standard Manual 04 2011 FIG NO N O gt Fulton Pressure Gauge Water Level Feed Water and Gauges Inlet Pressure Controllers Connections Water Level Boiler Vent Valve Controls Main Steam Top Exit Flue Valve Rear Exit Flue optional Safety Valve w Steam Pressure Gauge Boiler Control Box Burner Boiler Blowdown Boiler TDS Auto Feed Water Auto Blowdown shown Blowdown Pump Water Sample Cooler Note Component locations may vary from that shown FIG 1 RBC SERIES
83. eam isolating valve the pipe work should be secured near the boiler ensuring adequate flexibility exists in the pipe work between the steam valve and the securing point to minimise any loads imposed on the valve FIG 6 MAIN STEAM VALVE RBC Standard Manual 04 2011 Fulton 2 8 SAFETY VALVE N WARNING The factory fitted safety valve is designed to protect only the boiler This valve must not be used to protect other items The safety valve is factory fitted and pre set it MUST NOT be adjusted The discharge outlet should be piped to a safe discharge point and the pipe work so arranged that any trapped condensate will drain away from the valve a The lift pressure is indicated on the safety valve DO NOT adjust b The safety valve is designed to prevent the boiler from exceeding its design pressure c Any system connected to the boiler which is not capable of accepting boiler pressure must be protected by a separate safety valve set to the required pressure Note Safety Valve Outlet connections should be piped two sizes larger than the inlet connection size this will ensure there are no accumulation issues FIG 7 SAFETY VALVE 2 9 WATER LEVEL GAUGE SET All RBC series boilers are fitted with two Clifton type unless otherwise specified reflex water level gauges The water level gauge blowdown valves should be connected to the auxiliary blowdown line final connection to the blowdown valves bein
84. ed is effective The lower hand hole doors should be removed after one month and the interior of the boiler thoroughly examined If scale or sludge build up is observed a water treatment specialist should be consulted During normal operation the front ends of the turbulators will be burnt off this is normal and not a cause for concern Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are obtained Thereafter inspections should be carried out at six monthly intervals IMPORTANT New gaskets must be fitted every time a hand hole door is removed refer to Section 4 5 for fitting procedures 4 2 WEEKLY A All steam pipework valves and fittings will be very hot Do not operate the safety valve without protection Check for signs of leakage around the front door seal Leakage from the seal can cause a flame to short circuit in the furnace which can lead to over heating of the front tube plate a leak is detected shut down the boiler and replace the seal Check the hand holes and man holes for signs of leakage This is particularly important when the boiler is started from new or when gaskets have been replaced refer to Section 4 5 for fitting procedures for new gaskets Corrective action taken as soon as a leak occurs can prevent costly repairs later Check for signs of leaks on all valves and fittings and take the appropriate action Test all the boiler water level func
85. er should not be under pressure The boiler should be cold Close the blowdown isolation valve Using a screwdriver located as shown A push the Manual Blowdown Button up and make a quarter turn clockwise this will lock the button in position and open the blowdown valve Using the blowdown isolation valve to throttle the flow drain the boiler Note Skid units and plant rooms have internal drainage systems which require the same procedures If the boiler is not going to be used for some weeks see 3 9 3 Long Term Storage RBC Standard Manual 04 2011 22 3 6 Fulton STARTING THE BURNER FROM COLD 3 6 1 Practical Considerations AN CAUTION 23 When starting up the boiler it is prudent to minimise the thermal and mechanical stress caused by differential expansion of various parts of the boiler as they reach working temperature The shell temperatures is determined by the contained water steam temperature The furnace temperature which is higher is determined by the heat transfer furnace wall loading and gas temperature The tube temperature lies between the shell and furnace temperatures but is nearer the shell temperature Since all these components are virtually the same length they expand longitudinally by different amounts causing mechanical and thermal stress Whilst this is catered for in the mechanical design of the pressure vessel the life expectancy of the boiler can be affected if the boiler is frequently heated
86. eset If the level of water in the boiler falls below the second pre set limit during boiler operation the 2nd Low Water Alarm Reset Switch will illuminate the alarm will sound and the burner will shut down The water level must be restored before the alarm can be cancelled by pressing the switch High Water Indicator when fitted This lamp will illuminate and an alarm sound when the water level reaches a pre determined high level The feed water pump will stop When the water level falls to the normal working level the indicator lamp will extinguish the alarm cancel Burner Run Indicator Indicates that the burner is operating in the normal run position High Steam Pressure Alarm Reset Switch This switch will Illuminate and an alarm sound when the high limit pressure switch is tripped The switch alarm must be manually reset after the pressure has reduced to a safe level WARNING Before resetting this control ascertain the reason for the alarm and rectify Flame Failure Indicator Indicates the burner combustion control relay detects a flame failure condition Night Set Back Switch where fitted The Set Back Switch needs to be set to the On position at the end of the working shift This means the burner will only fire if the boiler pressure falls below a set stand by pressure This therefore reduces start up lead time at the beginning of the next shift when the Set Back Switch should be set to the off positio
87. g via soft copper tubing The valve fittings are 6 mm For operating details refer to Section 3 Operation FIG 8 FEED WATER LEVEL GAUGES RBC Standard Manual 04 2011 l 2 2 10 GAS SUPPLV The gas pressure requirement varies according to the burner size and the gas train selected Verify that the type and pressure of the gas available on the site is suitable for the burner fitted If the site gas pressure is too low it will be necessary to fit a gas booster system Consult Fulton Boiler Works if in doubt To minimise pressure drops eliminate all unnecessary bends and elbows in the pipe work between the gas meter and the inlet to the gas train Ensure that a gas cock of the correct size is installed as close as possible to the gas train All gas pipe work must be installed by Competent Persons in accordance with the gas regulations FIG 9 GAS BURNER INSTALLATION installation will change with the type of burner fitted 2 11 OIL SUPPLY Oil fired boilers are supplied with a matched automatic high low oil burner suitable for use with 35 SRNI fuel oil A single pipe system can be used where the suction is fully flooded however for systems where lift is required it will be necessary to install a two pipe system For more details consult the burner manufacturer s instruction manual The following points should be observed a Always install an oil filter b Use flexible pipe work for the
88. gen to a minimum and prevent thermal shock Water treatment chemicals should be used to remove the remainder of the dissolved oxygen Failure to do so will result in premature failure of the boiler tubes which will not be covered by warranty RBC Standard Manual 04 2011 l 2 2 6 BLOWDOWN VALVES The boiler is fitted with three blowdown valves one at each water level gauge assembiv and the main boiler blowdown valve at the front of the boiler The pipe work from these blowdown valves must be connected to a receptacle of approved design If in doubt consult Fulton Boiler Works or Health and Safety Executive Guidance Note PM60 which covers blowdown tanks and associated pipe work installation Never discharge blowdown from the boiler directly to a drain Where a high level of blowdown or automatic blowdown systems are installed serious consideration should be given to fitting a Blowdown After Cooling System Automatic Boiler Boi Blowdown oiler Valve Blowdown Isolation Valve Pneumatic Actuator FIG 5 AUTOMATIC BOILER BLOWDOWN Main Steam Valve 2 7 MAIN STEAM VALVE Distribution pipe work should be run from the main steam valve on top of the boiler to the steam delivery point s Care should be taken to ensure that adequate condensate drainage and expansion facilities are provided within the pipe work run s Steam Distribution Flange To prevent excessive loads being imposed on the main st
89. inate and alarms will sound due to the power restoration interlock refer to Section 3 3 Pump Only Off Pump amp Burner On switch description Note If the 2nd Low Water and High Pressure Alarm Reset switches illuminate and the alarms sound check that the burner mounted Burner On Off Reset Switch is in the Off position and then reset both alarms by pressing the switches f The burner motor will start and after going through the post purge pre purge interlock checks should fire after approximatelv 45 seconds Note Before leaving the boiler unattended the dailv operating tests see Section 3 7 should be carried out to check the functions of all the safetv interlocks For more detailed information on the burner firing sequence consult the burner manufacturer s Operation and Maintenance instructions RBC Standard Manual 04 2011 24 3 3 7 l DAILV OPERATING TESTS AN CAUTION If any of the following tests fail to function as described shut down the boiler immediately and consult Fulton Boiler Works Ltd Service Department With the burner firing carry out the following tests Note Ensure the correct water level is maintained during pressure build up If any part of the equipment is 3 7 1 Flame Sensor UV Photo Cell Check 3 7 2 Pump Check not operating correctly the fault should be investigated before the boiler is used Ensure all blowdown pipework is safe and discharged to a blowdown receptacle Rem
90. ined within the boiler cylindrical shell by the passage of hot gases through the furnace and tubes It should be noted that solids entering the boiler with the feed water can rapidly concentrate at areas of high heat transfer Such deposits can restrict heat transfer and consequently raise mean metal tempera ture which can cause corrosion and reduce safety margins possibly to the point of failure It is therefore strongly recommended that a reputable water treatment specialist is consulted prior to put ting the boiler into service Water characteristics are generally as specified in BS2486 1997 Treatment of Water for Steam Boilers and Water Heaters Table 2 Boilers operating in areas with high residual hardness high levels of Bicarbonate temporary hardness and low condensate return rates will have difficulty in maintaining Total and Caustic Alkalinity TDS fig ures within the specified limits when base exchange softening is used This will result in a tendency of the boiler water to foam causing unstable water level conditions pos sibly leading to priming and carry over In these instances particular care should be taken to establish a suitable water treatment programme and blowdown schedule in consultation with your water treatment specialist Cold feed water contains high levels of dissolved oxygen which is highly corrosive when released within a steam boiler Always pre heat the feed water to 80 85 C to reduce dissolved oxy
91. is possible that the steam load will rapidly decrease the pressure in the boiler causing a premature 2nd low water alarm This is normal and typical of priming where a boiler tries to maintain an overload condition resulting in unstable water conditions RBC Standard Manual 04 2011 30 l 3 3 11 FAULT FINDING Before calling the Fulton Service Department check the following a Gas isolating valve s are Open gas and dual fuel burners Oil isolating valve s are Open oil and dual fuel burners Oil storage tank contains adequate level of fuel d Oil filter s are not blocked e Water feed line from feed tank hotwell is Open f Water feed isolating valve on boiler is open g All blowdown valves are shut h Fuses or MCBs in the mains supply are not tripped j Thermal overload on the pump motor is not tripped Thermal overload on the burner motor is not tripped l Normal water level is visible in the water level gauges m Feed pump is primed and not air locked n Front door proof of closure microswitch is closed Before contacting the Fulton Service Department have the following information available a The model and size of the boiler b The boiler serial No The model and type of burner fitted Note Avery common problem is that when a boiler cools down the steam in the steam space condenses and gradually forms a vacuum If the feed wa
92. justment Off centre flame Check fuel pressure Check fuel valves Check fuel nozzle Readjust Check air inlet Check fan and thermal overload switch Check diffuser alignment in the blast tube Flue Check flue for blockage Boiler will not maintain Gas supply See above pressure Oil supply See above Steam pressure switch Scale build up in boiler Steam traps Dirty flue Steam overload RBC Standard Manual 04 2011 Check steam pressure switch readjust or replace Check Water Treatment advisor Check steam traps and replace as necessary Clean flue side of boiler Reduce 32 Fulton FAULT FINDING TABLE continued Problem Cause Remedy Wet steam boiler Too much boiler Dump return tank flush system primes treatment chemical or stop treatment for a week Steam traps See previous page Pump will not cut off Earth connection Check for tightness and clean Probes connections Check for tightness and clean Dirty probes Clean or replace Water level relay Replace Feed pump runs but does Air steam lock in pump Check for bad steam traps not put water into boiler Check for check valve in water feed line Reduce temperature of feed tank Blocked water feed line Check and clean if necessary Impellers damaged Replace pump Feed pump will not Probe connections Check for tightness and start in time clean the connections Dirty probes Clean or replace Water level relay Rep
93. lace Earth connection Check for tightness and clean Low water alarm burner Probe connections Check for tightness and clean shut off will not act in time the connections Dirty probes Clean or replace Water level relay Replace Earth connection Check for tightness and clean Starting the boiler the Boiler is completely filled Blowdown the boiler to a high limit steam pressure with water normal water level limit is illuminated and the burner stops On off pressure switch has Check pressure switch replace failed as required Note For more detailed fault finding on the burner consult the burner manufacturers Installation and Maintenance instructions 33 RBC Standard Manual 04 2011 Fulton 4 MAINTENANCE SECTION 4 4 1 GENERAL To ensure the continuing efficiency of the boiler regularly carry out regular routine maintenance procedures as detailed below AN WARNING Lifting Equipment Make sure that lifting equipment complies with all local regulations and is suitable for the job You can be injured if you use faulty lifting equipment Make sure the lifting equipment is in good condition IMPORTANT any fault is found during these procedures shut down the boiler immediately and consult Fulton Boiler Works Ltd Note It is essential that regular checks are made to ensure scale build up is not taking place within the boiler Such checks will ensure that water treatment being applied to the boiler water fe
94. llel hinge system FO2170 FIG 25 DOOR HINGE AND LATCH ASSEMBLV RBC Standard Manual 04 2011 4 8 Fulton FEED WATER DISPERSER N CAUTION DO NOT use unheated or untreated feed water which can result in premature tube failure bv oxvgen corrosion RBC Boilers are fitted with a feed water disperser removable for cleaning The holes in the disperser are sized to give an exit velocitv sufficient to ensure rapid mixing of the boiler water and the cooler feed water reducing temperature gradients within the water to a minimum In order to reduce oxvgen corrosion to the tubes and prevent thermal shock it is imperative that feed water entering the boiler is heated to 80 85 C The solubility of oxygen in water reduces to minimum at 85 C on initial start up this may not be possible As part of the water treatment programme chemicals will be dosed into the boiler feed water line and or the boiler feed water tank The nature of many of these chemicals is that they react when there is a rapid rise in temperature such that dissolved solids are precipitated and fall out of solution as a sludge The first major change in temperature to the feed water is as it enters the feed water disperser as a result some solids will be precipitated within the disperser the majority will be washed through however some may remain as deposits The disperser should therefore be removed inspected and cleaned at each inspection interval i
95. mm PN16 IBC 15003 VALVE SAFETY DN40 65 ARI Part No Description 210RG240CH RB2100 FULTON HORIZONTAL 10549 VALVE BALL 1 4 ART 45T 12456 GAUGE PRESSURE 6 200PSI 13826 VALVE CHECK 1 1 4 RK41 E 10565 TEE BRONZE 1 4 EQUAL 060RX324UK PANEL GAS 60 180HP AOTC 14821 VALVE SAFETY DN40 11 2 SA2000 CLIFTON SAMPLE COOLER 14491 BURNER GAS XGN3000 38M RBC Standard Manual 04 2011 Quantity G PY AN PO A c Quantity 7 a aba ANG oO A ago a Quantity 1 1 1 1 2 1 1 1 1 Assy Description 210RG140SX RBC2100 GAS BOILER Assy No Description 210RG140UK RBC2100 GAS BOILER Part No 12413 13293 10423 13277 12597 12412 11786 13424 13296 12449 5 2000 14658 13209 14465 10549 11824 13016 SA3010 13069 13826 14293 13037 13123 13033 15003 O60RX324SX Part No 13277 13217 13296 13080 13293 13209 13123 12413 12412 060RX324UK 13069 11824 14658 3037 12449 14465 13016 12456 15003 5 2000 11786 SA3010 10423 13826 14293 Fulton RBC2100 GAS BOILER SX Spirax UK Standard Description GASKET 40mm PN16 IBC BRUSH TUBE 44mmSINGLE PROBE BRASS 36 LONG VALVE STOP FLANGED DN32 PROBE BODY LP30 HIGH GASKET 32mm PN16 IBC GASKET 25mm PN16 IBC LABEL RB REGISTRATION BRUSH HANDLE 3250mm SWITCH DOOR LIMIT DB4 CLIFTON SAMPLE COOLER BURNER GAS MGN2800X T3D VALVE DN100 ANGLE PAT N VALVE GLOBE BR
96. mm PN16 IBC GASKET 32mm PN16 IBC RBC Standard Manual 04 2011 Quantity 2 lA ch sch IA sch ech A OW BR NN O Quantity oh a a a EA Oa BR PS a 104 Fulton RBC1500 OIL BOILER with ECONOMIZER and MOD WATER SX Spirax UK Standard Assy No Description 150RG140ESM RBC 1500 ECON MOD WATER 105 Part No SA3010 15005 SA2000 15002 060RM324SX 14181 14997 12444 12449 12456 12597 10418 11824 13277 13292 13294 13016 13033 13037 13069 13123 13209 13826 14589 12412 14465 14659 14999 14998 10566 14661 14915 13826 14986 11786 11824 Description PRESSURE GAUGE ASSY VALVE SAFETY DN25 40 ARI CLIFTON SAMPLE COOLER VALVE SAFETY DN32 50 ARI PANEL D F GAS MODULATING VALVE CHECK DN32 DCV2 VALVE FEEDWATER DN32 MOD GAUGE REFLEX CLIFTON 350 SWITCH DOOR LIMIT DB4 GAUGE PRESSURE 6 200PSI PROBE BODY LP30 HIGH PROBE BRASS 7 LONG GASKET 15mm PN16 IBC VALVE STOP FLANGED DN32 BRUSH TUBE 38mmSINGLE BRUSH HANDLE 2950mm VALVE BLOWDOWN 32mmKBV20 PROBE TIP 1000mm LP30 GASKET 100mm PN16 IBC FACIA FULTON FR HOR 3mm GASKET 65mm PN16 IBC VALVE DN100 ANGLE PAT N VALVE CHECK 1 1 4 RK41 E PUMP WATER CR5 24 GASKET 32mm PN16 IBC VALVE GLOBE BRONZE 1 2 PROBE BODY LP20 GAUGE TEMP 4 0 300 DEGc GAUGE TEMP 4 0 120DEGc GAUGE PRESSURE 4 250PSI PROBE PA20 PRE AMPLIFIER VALVE BALL 1 1 4 PN16 VALVE CHECK
97. n supply lines each line having a manual cock a governor and solenoid operated valves The governors maintain a consistent pressure of fuel entering the burner and are adjustable The solenoid valves are electronically controlled by the burner programmer For specific details consult the burner manufacturers Instruction Manual RBC Standard Manual 04 2011 Note oil burner is illustrated for specific details consult the burner manual supplied with the boiler Fulton PLA CIA Ly PUMP DFI ri A CH OH End LOW WATER CRESS ALAKN HESE ALLARM RESET BUA KEP uH POWER CH Tet LRA WATER FRLURE e FIG 15 BOILER CONTROL PANEL FIG 16 BURNER CONTROL PANEL RBC Standard Manual 04 2011 3 3 Note Note Fulton BOILER CONTROL PANEL Boiler controls and indicators are housed in a control panel mounted on the side of the boiler These are as follows Power Isolator Switch Control panel power supply ON OFF switch mounted on the panel door Power On Indicator Indicates that the door mounted power on isolator is in the ON position and that the panel is electrically live A WARNING The Power On indicator is derived from one phase It is possible for the Power On indicator supply phase to be down leaving the other two phases live Always isolate the supply before working on the panel Pump Only Off Pump amp Burner On This rocker switch has three
98. n to enable the boiler to reach normal operating pressure RBC Standard Manual 04 2011 3 4 3 4 1 Fulton BURNER MOUNTED CONTROL PANEL consult the specific burner manual Burner controls and indicators are mounted on the burner The following controls are typical for a dual fuel burner but reference should be made to the burner manufacturer s Operating Manual for the particular type used Burner On Off Reset Switch Three position switch used to switch on off and or reset the burner Lockout Indicator Indicates the burner combustion control relay detects a flame failure condition The burner controller can be reset by setting the Burner On Off Reset Switch to the RESET position Hand Indicator This lamp will illuminate when the hand auto switch mounted inside the burner control panel is in the hand position normally used for commissioning only Auto Indicator This lamp will illuminate when the hand auto switch mounted inside the panel is in the auto position High Pressure Indicator This lamp is not wired when a high steam pressure alarm lamp is provided the boiler control panel Modulating Controller Controls the firing of the burner within the pressure band selected INTERNAL ECONOMIZER Operation Feed water from a constant running pump is passed through a modulating feed water control valve and then through the economizer before entering the boiler Heat is extracted from the boiler exhaust gases by the e
99. oiler shell to automatically maintain the water level in the boiler between set limits If the water should fall to an unsafe level the burner is cut out and an alarm is sounded The probes are located in two 100 mm diameter standpipe flanges mounted on either side of the boiler centre line towards the front of the boiler A standard boiler is fitted with Feed water pump On Off 1st Low Water and 2nd Low Water probes 15mm TDS surface Blowdown connection is supplied fitted with a blank flange If TDS monitored system is fitted it should be interlocked such that the valve will not open when the feed water pump is running RBC Standard Manual 04 2011 Fulton Watert Level Probes Main Steam Valve TDS Controller Pressure Gauge may be top mounted or panel mounted High Limit Switch Operator Control Panel High Low Pressure Switch Power On Isolator Switch Control Pressure On Off Switch Burner Control FIG 13 BOILER CONTROL BOX Panel VSD Enclosure Gas Booster when required Gas Supply Burner Note Burners and their installation will vary with boiler model and burner size FIG 14 GAS BURNER INSTALLATION RBC Standard Manual 04 2011 3 2 Fulton BOILER FITTINGS AND CONTROLS continued Steam Pressure Controls Pressure controls are mounted on the side of the control box These are as follows a Control Pressure On Off Switch Controls the ON Off cycle of the burner switching
100. on from either PUMP ONLY or OFF the power restoration alarms will be activated The alarm can be cancelled by pressing the 2nd Low Water Alarm Reset switch 2 The2nd Low Water alarm can only be cancelled if the boiler water level is above the 2nd low water level If the alarm cannot be cancelled allow the feed pump to restore the water level to the normal working level approximately midway up the sight glass and then reset the alarm Pump off on switch This switch is only used for evaporation and low water tests Interrupts the power supply to the feed pump contactor coil RBC Standard Manual 04 2011 3 3 Fulton BOILER CONTROL PANEL continued Sequence manual auto switch when fitted Used to select either manual or automatic sequence step control In the manual position the burner will operate under the direct control of the master pressure con troller mounted in the steam header distribution pipe work The boiler mounted high pressure and on off pressure switches are still functional 1st Low Water Indicator This lamp will be illuminated and an alarm sounded when the water level in the burner falls to the 1st low water level The burner will shut down and the alarm will continue to sound until the water level is restored to a safe working level The alarm will then cancel the indi cator lamp will extinguish and the burner will automatically restart 2nd Low Water Alarm Reset Switch Sounds an alarm on switch on press to r
101. outlet The flue manufacturer installer must be consulted at an early stage to ensure a correct mating component for flue connection see fig 3 The flue diameter must be the same or larger than the boiler flue outlet A reduction in flue diameter will cause additional resistance which could have an adverse effect on combustion RBC Standard Manual 04 2011 Fulton 2 4 FLUE OUTLET continued Model A C PCD Holes O Holes 15mm dia equi spaced Material mild steel FIG 3 FLUE FLANGE RBFlueConnection O O O O O O Avoid fitting 90 short radius elbows 90 tees and long horizontal runs wherever possible All horizontal flue runs should have a rising pitch of 15 minimum to prevent condensate build up and subsequent corrosion Oil fired boiler installations are generally more critical because of the sulphur content in the fuel and the higher dew point temperature Specialist advice should be obtained on flue material and insulation Feed Water Inlet Valve Feed Water Inlet Check Valve FIG 4 FEED WATER INLET RBC Standard Manual 04 2011 Fulton 2 5 WATER SUPPLY see Recommended Water Conditions Section 5 WARNING DO NOT use unheated or untreated feed water which can result in premature tube failure by oxygen corrosion The quality of the feed water will effect the life and performance of a steam boiler Steam is produced by heat transfer from the heat source into the water conf
102. ove the burner UV photocell from its plug in connection on the side of the burner and cover the detection window to exclude all light The burner control should immediately 2 3 sec gas 5 sec oil go to a lockout flame failure condition and will require manual resetting Clean the UV photocell before replacing it FIG 17 TYPICAL FLAME SENSOR REMOVAL a Lower the water level in the boiler either by evaporation or by opening the main blowdown valve with the key provided operate the bypass system for boilers fitted with auto blowdown b Observe the water level in the water level gauges and as the water level falls check that the feed water pump starts c Shut the main blowdown valve if opened and ensure that the feed water pump continues to fill the boiler to the correct level then switches off 3 7 3 1st Low Water Check Note Water levels and probe lengths should be noted on commissioning and recorded with the boiler 25 a Turn the Pump On Pump Off Switch on the boiler control panel to the pump off position b Lower the water level in the boiler either by evaporation or by opening the main blowdown valve RBC Standard Manual 04 2011 Fulton 3 7 4 2nd Low Water Check a Repeat the procedure described in Section 3 7 3 a to c but allow the water level to continue to fall either by evaporation or maintaining the main blowdown valve open Before the water level falls below the level of the wate
103. ow Pressure Switch Control Pressure Switch FIG 24 PRESSURE SWITCH LOCATIONS 4 6 1 Controls The standard boiler is fitted with steam pressure switches as follows 41 High Limit Pressure Switch proportional non adjustable when fitted High Low Pressure Switch Control Pressure Switch Burner Control Pressure Switch Oil only They are located on the control box together with a syphon pipe pressure test point and steam pressure gauge The Control Pressure Switch controls the on off cycle of the burner switching the burner off when the desired steam pressure is reached and switching it on when the steam pressure falls The High Limit Pressure Switch is a maximum steam pressure switch which has to be set to operate at least 0 5 bar higher than the Control Pressure Switch Normally the High Limit Switch does not operate but if the Control Pressure Switch fails and steam pressure rises above the adjusted steam pressure the High Limit Switch should switch off lock out the burner illuminate the High Limit Pressure lamp and sound the alarm Should this happen switch the boiler to pump only and wait until the steam pressure is discharged Check the connection to the pressure switch replace as required The High Low Pressure Switch switches the burner between high and low fire RBC Standard Manual 04 2011 Fulton 4 6 2 Adjusting the Pressure Switches a Start the boiler Shut the main steam valve Set the con
104. phon and Cock Alternative additional valves mountings may be fitted according to specific requirements Boiler combustion is provided by gas oil or dual fired burners designed for high low flame operation Combustion air is normally controlled by a motorized butterfly damper incorporating a proof of closure interlock Burner controls and a fuel pump unit oil fired models only are mounted on the burner Note Consult burner manufacturer s Operation and Maintenance instructions for more details 1 2 TECHNICAL DATA for a full specification see General Data Section 5 AN CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treat ment plants are NOT SUPPLIED by Fulton It is the responsibility of the operator to ensure adequate supplies of chemical are available at all times including commissioning Costly repairs could be required should the plant operate without chemicals or the wrong dosage of chemicals RBC Standard Manual 04 2011 Fulton Safety Valve Flue Flue Adaptor supplied loose Boiler Vent Rear Flue and Economizer used when filling or optional emptying the boiler Note Component locations may vary from that shown FIG 2 BOILER VENT SAFETY VALVE and TOP FLUE RBC Standard Manual 04 2011 Fulton 2 INSTALLATION SECTION 2 2 1 GENERAL 2 2 SITING CAUTION The installation of an RBC Series Steam Boiler must be carried ou
105. pment is in good condition Remove the hand hole and manhole doors and thoroughiv inspect the internal surfaces of the boiler paving particular attention to the junction of the tubes with the front tube plate and the tubes for signs of pitting Anv deposits should be removed and vour water treatment specialist consulted Ensure there are no accumulated deposits of sludge in the bottom of the boiler Remove the feed water disperser inspect and clean Replace the man hole and hand hole door gaskets refer to Section 4 5 for fitting procedures Open the boiler front access door with the burner mounted on it as described below It will be necessarv to disconnect the gas supplv authorised personnel oniv from the gas train and oil supplv from the oil lines to allow the door to swing open Undo the four retaining nuts The two on the hinge side bv two complete turns See 4 7 Open the door sufficientiv to allow full access to the furnace and tube ends h i 35 Where retarders are fitted they should be removed some burning of the retarders at the inlet end is normal Remove the access panel from the economizer check for clogging or blocking of the finned tubes should the tubes need to be cleaned extreme care should be taken not to damage or distort the fins Maintenance instructions for control and safety devices fitted to the economizer system should be fully observed Refit the economizer access panel RBC Standard Manual 04 2
106. r level gauge check that the 2nd Low Water Alarm Reset switch illuminates the alarm sounds and the burner shuts down Shut the main blowdown valve if opened Set the Pump On Pump Off Switch to the pump on position d Check that The feed water pump starts restores the water level to a safe working level then stops The 1st Low Water alarm cancels The 1st Low Water Indicator lamp extinguishes but the burner does not start The 2nd Low Water alarm continues to sound The 2nd Low Water Alarm Reset switch remains illuminated e Press the 2nd Low Water Level Alarm Reset switch f Check that The 2nd Low Water alarm cancels The 2nd Low Water Alarm Reset switch extinguishes The automatic burner firing sequence commences To reduce the possible down time and a loss of pressure to the steam load the tests detailed in 3 7 2 3 7 3 3 7 4 can be accomplished by isolating the feed pump using the pump on off switch on the boiler control panel as 3 10 and allowing the water level to fall by evaporating steam to the system Once the 1st Low Water Level Alarm is activated the water level can be lowered to the 2nd Low Water Level by using the main blowdown valve When the 2nd Low Water Alarm sounds close the blowdown valve turn the feed pump on off switch to pump on Once the 1st Low Water Level cancels the burner should remain off but the 2nd Low Water Alarm should continue to sound
107. separate functions In the PUMP ONLY and PUMP amp BURNER ON positions the power supply is switched through to the control system It is a mandatory requirement of the AOTC and Gas Supply Standards that when the control system is first energised or reenergized power restoration it must go to a fail safe shutdown position sound an alarm and require manual resetting to cancel the alarm The alarm condition when activated is cancelled by resetting the 2nd low water reset switch PUMP ONLY Position This position should only be selected to fill the boiler The normal functions of the level control alarm system are overridden to prevent a continuous alarm while the boiler is being filled The pump off level control will function normally and switch the pump off once the correct water level is reached 1 The burner mounted Burner On Off Reset Switch should be in the OFF position during the filling process 2 The Pump On Pump Off Switch should be in the PUMP ON position Both alarms will be cancelled when pressing the reset switches irrespective of the water level in the boiler OFF Position In this position the burner feed pump and control system are off PUMP amp BURNER ON Position In this position both burner and pump will run under automatic control providing that the burner mounted Burner On Off Reset Switch is in the ON position and the Pump On Pump Off Switch is in the PUMP ON position 1 When selecting this positi
108. t by competent personnel accordance with all relevant safety regulations It is the responsibility of the installer to ensure that these regulations are complied with A WARNING Lifting Equipment Make sure that lifting equipment complies with all local regulations and is suitable for the job You can be injured if you use faulty lifting equipment Make sure the lifting equipment is in good condition The boiler house must be sufficiently large to allow easy and safe access to all parts of the boiler for operational and maintenance purposes Typical boiler dimensions are given in the General Data Section 5 The flooring must be level laid in a non combustible material and be of sufficient strength to support the boiler 2 3 VENTILATION An adequate supply of clean fresh air is necessary for safe efficient boiler operation Ventilation should be provided at both high and low level to BS6644 1991 and IGE UP 10 Edition 2 2 4 FLUE OUTLET Note The height and type of flue will be subject to local planning regulations and approvals and to the requirements of the Clean Air Act Before erecting a flue Public Health Authority and Planning permission must be obtained The following information is intended to provide assistance where the installation of a simple flue is required Where multi boiler flues are necessary or difficulties could be experienced specialist advice must be obtained Boilers are fitted with a flanged flue
109. ter line is open the boiler will syphon water in attempting to equalise the pressure The appearance in the water level gauges is the same if they are empty or fully flooded If the sight glasses appear empty but the water level control alarm s have not sounded it is highly probable that the boiler is flooded Allow air into the system and lower the water to the normal operating level 31 RBC Standard Manual 04 2011 Starting Fulton FAULT FINDING TABLE Cause Power supply Gas supply Low water probe Loose wire connection Control circuit dead Remedy Check fuses or circuit breaker Check for gas pressure Check main gas cock is open Check low water probes Check connections to all components Door interlock microswitch Gas burner will not Gas supply Gas pressure switch s Air pressure switch Check for gas pressure Reset gas pressure switch Check air pressure switch Check fan and thermal overload switch Oil burner will not Oil supply Fuel pump Check for oil in storage tank Check oil feed line is open Check oil solenoid valves Check oil pump is de aerated Check oil strainer Burner will not start Burner control locked Ignition Reset Check ignition electrode and readjust or clean Check transformer Flame failure Flame sensor Burner programmer Clean or replace Check functions or replace Poor combustion Fuel flow Air ad
110. the guidance of the operator in the use of the RBC Series Steam Boilers and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health BOILER FITTINGS AND CONTROLS The following brief description of the fittings and controls used on the RBC Series boiler is intended to provide the operator with a basic understanding of the operating principles which is essential for the continued efficient use of the boiler Main Steam Valve Steam outlet stop valve fitted centrally on the top centre line of the boiler Steam Vent Valve Fitted to the rear on the top centre line of the boiler Steam Pressure Gauge Fitted to the control box mounting plate on the side of the boiler Blowdown Valves A main boiler blowdown valve fitted on pipe work at the front of the boiler on the underside centre line and one blowdown valve for each water level gauge set Feed Water Valve Water supply inlet stop valve mounted on the side of the boiler Feed Water Non return Check Valve Water supply NRV mounted on the side of the boiler directly under the main feed water inlet valve Water Level Gauge Set Two Clifton type reflex gauge sight glasses mounted on the side of the boiler Boiler Water Sample Valve Fitted behind the feed water inlet on the side of the boiler Low Water Safety Relays and Feed water Pump Relays These relays operate in conjunction with probes suspended in the b
111. tion from many sources including heat oxygen stress and overdosing from certain types of water treatment This takes the form of material oxidation hardening embrittlement and cracking which may result in gasket failure Steps must be taken to minimise the effects of such attacks Water treatment and oxygen attack can be combated by ensuring that the gasket is aligned correctly so that only the extreme edges of the gasket are exposed If a new gaskets leaks after fitting this is almost certainly due to incorrect seating or alignment As such gaskets are very flexible it is possible to cure the leak by excessive tightening but such an action will seriously reduce the life of the gasket and cause problems later Undue stress can be avoided by tightening just sufficiently to stop any leakage when fitting cold and before firing the boiler Fire the boiler and then gradually warm the boiler up allowing the increasing steam pressure to take over and complete the seal The will allow the gasket material to contract naturally and follow the topography of the mating surfaces The securing nut can then be tightened gently by say a quarter of a turn to ensure a snug fit and prevent the seal from being broken when the boiler is cold and under negative pressure Gentle warming of the boiler on initial firing after maintenance will also help to ensure that the rubber cures to shape If the rubber post cures the elastic memory will be destroyed and
112. tions by evaporation e g switch off the boiler feed pump see Starting the Burner section 3 6 Carry out routine maintenance checks on the burner as recommended by the manufacturer s Installation and Maintenance instructions Check the flame failure controls by removing the burner flame sensor from its plug in connection on the side of the burner and covering the detection window to exclude all light The burner control should immediately go to a lockout flame failure condition and will require manual resetting Clean the flame sensor before replacing it RBC Standard Manual 04 2011 34 4 3 SIX MONTHLY Fulton A WARNING The boiler must be completely cold before carrying out any of the following procedures a 0 Ensure that the following valves are Shut The main steam stop valve The feed water isolating valve The fuel gas oil valves Ensure that the power supply to the boiler is switched Off A CAUTION The boiler and attaching parts will retain heat long after the boiler has been shut down Always use protective clothes and extreme caution when working on a hot boiler Empty the boiler by allowing air into the boiler via the boiler vent valve and draining through the boiler blowdown valve A WARNING Lifting Equipment Make sure that lifting equipment complies with all local regulations and is suitable for the job Vou can be injured if vou use faultv lifting equipment Make sure the lifting equi
113. to carry out the statutory inspection The scope of a full insurance strip down is such that it should only be attempted by persons competent to do so who have had the necessary training and have the required test equipment Fulton Boiler Works can offer this service if required The engineering surveyor may require the removal of the ceramic fibre insulation around the periphery of the front tube plate to facilitate inspection of the shell to tube plate weld The standard Fulton service kit includes replacement ceramic fibre material which must be glued in place with the adhesive supplied It is vital the material is fitted ensuring the ends of the fibre face into the centre of the boiler For burner maintenance refer to the manufacturer s Installation and Maintenance instructions RBC Standard Manual 04 2011 38 Fulton 4 4 5 FITTING NEW GASKETS Fig 6 and 7 4 5 1 General ZIN CAUTION TOPOG E gasket have a finite life after installation and must be renewed annually It is important that the instructions given this section are adhered to The RBC Series boilers are fitted with TOPOG E gaskets in all the inspection holes of the boiler These gaskets work very well and millions have been safely used over the last 30 years however it is absolutely essential to observe a few simple rules in order to get the best performance from your installation Elastomeric Vulcanizates which form the basis of TOPOG E gaskets undergo degrada
114. to position using a high temperature adhesive Inspection of the tube plate to shell weld will require insulation to be removed it is important after inspection to replace with new high temperature end on fibre available with adhesive from Fulton See section 4 4 Boiler Tube Front Access Door Plate Insulation Burner Blast Tube Door Insulation FIG 11 FRONT ACCESS DOOR INSULATION RBC Standard Manual 04 2011 2 14 ECONOMIZER Fulton RBC Standard Manual 04 2011 Fulton Water Level Feed Water Gauges Inlet Pressure Gauge Connection Water Level Controls Boiler Vent Valve Steam Main Steam Top Exit Flue Pressure Valve Rear Exit Flue optional Gauge fety Val TDS Control SSES ANG ler may be top mounted or panel mounted Boiler Control i Box s Burner Boiler Blowdown Boiler TDS Auto Feed Water Boiler Auto Blowdown shown Blowdown Pump Water Sample Cooler Note Component locations may vary from that shown FIG 12 GENERAL ARRANGEMENT RBC Standard Manual 04 2011 3 1 3 2 Fulton 3 OPERATION SECTION 3 A CAUTION Before putting the boiler into operation it must be fully commissioned In order to ensure safety the commissioning must be carried out by a Fulton engineer The commissioning of the boiler by any other person without the specific written authority from Fulton Boilers will invalidate the warranty GENERAL The following instructions are given for
115. to prevent the constant running feed water pump from overheating should the modulating feed water control valve fully close A 5mm orifice plate fitted in the spill back line before entering the tank as well as tank inlet dip pipe are also recommended RBC Standard Manual 04 2011 20 3 3 42 BOILER PLATFORM The platforms where fitted are mounted to the boiler base frame Thev are designed to allow easv maintenance access to the components on the top of the boiler i e the water level probes main steam valve vent and safetv valves It is the responsibility of the user to ensure that a site risk assessment is carried out for the safe use of the ladders and working at height on the platform FIG 16A TVPICAL BOILER PLATFORM 3 5 FILLING THE BOILER 1 Ensure the following valves are Open Steam pressure gauge isolating valve All valves in the water feed line Water gauge isolating valves Air release valve O 2 Ensure the following valves are Shut a Main steam valve b Main blowdown valve ai Water gauge blowdown valves d All valves in the gas oil train to the burner 9 Ensure that the Burner On Off Reset Switch is set to Off 4 Ensure that the Pump On Pump Off Switch is in the Pump position and that the Pump Only Off Pump amp Burner On Switch is in the position 5 Turn the door isolator to the On position 6 Place the Pump On Pump Off
116. trol pressure switch to its maximum d Set the high limit pressure switch to 0 5 bar below the safety valve setting e Allow the steam pressure to rise until the high limit pressure switch trips On the steam pressure gauge check that the pressure is not less than 0 5 bar below the safety valve lift pressure If the pressure is incorrect repeat steps b d and f Open the main steam valve to lower the steam pressure g Reset the control pressure switch to the required working pressure and the high low pressure switch to 0 3 0 5 bar below the control pressure switch setting h Shut the main steam valve j Reset the high limit pressure switch and allow the steam pressure to rise until the high low pressure switch reduces the burner to low fire and then the burner shuts down under the control pressure switch Readjust if necessary to achieve the required settings Note The requirement for a difference between the control and high limit pressure switches is to prevent unnecessary high limit steam pressure faults tripping the burner at no load conditions The residual heat in the furnace the flue pipes and the door refractory is capable of raising steam pressure slightly causing the high limit pressure switch to trip out RBC Standard Manual 04 2011 42 4 7 43 Fulton FRONT ACCESS DOOR ADJUSTMENT AND SEAL A WARNING When handling ceramic fibre always follow the local regulations regarding such
117. urs Medium Term Days Long Term Weeks Evaporation Test Fault Finding MAINTENANCE General Weekly Six Monthly Annually Fitting New Gaskets General Fitting Instructions Steam Pressure Switch Adjustment Controls Adjusting the Pressure Switches Front Access Door Adjustment and Sealing Feedwater Disperser Water Level Probe Replacement GENERAL DATA Boiler Specifications Boiler Dimensions Recommended Water Conditions Wiring Diagrams SPARE PARTS RBC Standard Manual 04 2011 SECTION Fulton A SAFETY The instructions provided for the operation and maintenance of the boiler MUST be observed Failure to do so could result in damage to the boiler and serious personal injury A WARNING It is the responsibility of the installer to ensure all parts sup plied with the boiler are fitted in a correct and safe manner AN WARNING Do not try to do repairs or any other maintenance work you do not understand Obtain a Service Manual or call a Fulton Service Engineer AN WARNING Understand the electrical circuit before connecting or discon necting an electrical component A wrong connection can cause injury and or damage AN WARNING A defective boiler can injure you or others Do not operate a boiler which is defective or has missing parts Make sure that all maintenance procedures are completed before using the boiler A WARNING The installation of Gas appliances including the flue system should only be carried
118. utting out the defective area and replacing with new fibre ensure the correct adhesive is used r Examine the end of the burner blast tube where it extends through the door into the furnace Clean off any deposits paying particular attention to the internal lip where deposits can cause irregular flame patterns s Inspect the rear smoke box door seals for deterioration and replace if necessary t Close the hinged front access door by reversing the opening procedure see 4 7 u Reconnect the gas oil connections v Drain and flush the feed water hotwell tank clean any filters and the strainer in the feed line before the pump w Drain and flush out the blowdown separator x Carry out routine maintenance to the burner as detailed in the manufacturers Installation and Maintenance instructions Note Depending upon the mode of operation it may be found that the six monthly interval can be extended possibly to an annual service It is strongly recommended however that the interval should be 6 months from initial start up until such times as a pattern of use and the condition of the boiler after a typical 6 months can be established 4 4 ANNUALLY It is a requirement of the Factories Act and Pressure Systems Regulations that the boiler is internally inspected and re certified at not more than 14 month intervals It is normal practice to carry out an annual service during which your insurance surveyor would attend
119. v RBC Standard Manual 04 2011 55 Fulton 5 4 WIRING DIAGRAMS continued RBC Standard Manual 04 2011 y LHI MOI Buz Fulton 5 4 WIRING DIAGRAMS continued L000 90493 aff U H Py H PSES 15 05 HL YON IS ANY 01 1411421 LA 184 o EDET DL e ae oe I UJAdad9 ee HATH WHY LHON MGI Jk 141114 41 Yet Hel Ing 14548 MOT D DEN ga LA 09 B 1 AH LO ES Il LOH KI 15 0501 531104 13904 100 10549 404 11111813 TAN T d 1041 03 14 1 131114 411 ut WSL HEIH E RBC Standard Manual 04 2011 Fu 2000 Wes gt gt 5831108 1303 1 00 3 10 SVD 304 2110 mem 11013413 13 x SONIMVUG 01 43434 NOLLINYASNI x 240 1041 03 14 4171 Aes WIIWAN JASSI 404 SIDNVH Jo NOILV201 lt 310 30 831114 41 HDIH 2 NO 440 MO PUZ 01 15 4 E F UJ WA Iv g31 VM MOT PU g3l VM 0115 H 1 031113 31 WHV IV HDIH 13538 YILVM MOT Puz L 01108 13538 HILVM MOT O e gt f 40123135 HILIMS LI EE 5 4 WIRING DIAGRAMS continued 58 Fulton 5 4 WIRING DIAGRAMS continued 000 90d93 INSSI J
120. y And S S AQ W 84 Assy 125RO140SX Assv No 125RO140UK 85 Description RBC1250 OIL BOILER Description RBC1250 OIL BOILER Fulton RBC1250 OIL BOILER SX Spirax UK Standard 060 245 11608 Part 060RO324UK 13209 13069 SA3010 10423 13141 SA2000 13123 14584 13294 13276 12449 14465 13037 13292 12456 12412 11786 13036 11824 15002 11608 14290 RBC Standard Manual 04 2011 Description PUMP WATER CR3 21 GASKET 100mm PN16 IBC GASKET 65mm PN16 IBC VALVE STOP FLANGED DN25 VALVE SAFETY DN32 50 ARI SWITCH DOOR LIMIT DB4 VALVE GLOBE BRONZE 1 2 GASKET 80mm PN16 IBC VALVE BLOWDOWN 25mmKBV20 FACIA FULTON FR HOR 3mm GAUGE PRESSURE 6 200PSI GASKET 15mm PN16 IBC GASKET 25mm PN16 IBC PROBE BRASS 36 LONG PROBE TIP 1000mm LP30 BRUSH TUBE 38mmSINGLE PROBE BODY LP30 HIGH BRUSH HANDLE 2950mm BURNER OIL NOL 50 34 T3L VALVE DN100 ANGLE PAT N CLIFTON SAMPLE COOLER PRESSURE GAUGE ASSY GASKET 32mm PN16 IBC PANEL OIL 75 180 AOTC VALVE CHECK 1 41 5 Description PANEL OIL 60 180HP AOTC VALVE DN100 ANGLE PAT N FACIA FULTON FR HOR 3mm PRESSURE GAUGE ASSY PROBE BRASS 36 LONG VALVE BLOWDOWN 25 20 CLIFTON SAMPLE COOLER GASKET 65mm PN16 IBC BURNER OIL NOL 50 34 T3L BRUSH HANDLE 2950mm VALVE STOP FLANGED DN25 SWITCH DOOR LIMIT DB4 VALVE GLOBE BRONZE 1 2 GASKET 100mm PN16 IBC BRUSH TUBE 38mmSINGLE GAUGE PR

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