FULTON FT-C Installation And Operation Manual
  1. Manuals
  2. Brands
  3. FULTON Manuals
  4. Heater
  5. FT-C
  6. Installation and operation manual

FULTON FT-C Installation And Operation Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

-Fillon
INSTALLATION AND
OPERATION MANUAL
Vertical Coil Design
Serial/ National
Board Number
Model
Fulton Order
Sold To
Job Name
Date
FTCS-/OM-2013-0227
Thermal Fluid Heaters
Models FT-C and FT-5

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the FT-C and is the answer not in the manual?

Questions and answers

Related Manuals for FULTON FT-C

Summary of Contents for FULTON FT-C

  • Page 1 -Fillon INSTALLATION AND OPERATION MANUAL Vertical Coil Design Thermal Fluid Heaters Models FT-C and FT-5 Serial/ National Board Number Model Fulton Order Sold To Job Name Date FTCS-/OM-2013-0227...

  • Page 2: Table Of Contents

    FTCS-IOM- 2 0 7 3·0227 Questions? Call (31 SJ 298·5121, or visit us online at www.fulton.com TABLE OF CONTENTS FILLING PROCEDURE FOR SYSTEMS EQUIPPED WITH INERT BLANKETS ....... .3-4 Introduction Circulating Pump ....................3-5 Overview ......................1-2 PUMP WITH MECHANICAL/AIR COOLED SEAL ................3-5 Warnings &...
  • Page 3 AIR FILTER BOX SWITCH ......................4-8 TEMPERATURE LIMIT(S) ......................4-8 HIGH/LOW GAS PRESSURE SWITCH ................... 4-8 Troubleshooting ....................4-8 FLOW CIRCUIT/ CIRCULATING PUMP(S ) ..................4-8 Parts ........................5 - 2 Standard Warranty for Fulton Thermal Fluid Heaters .......... 5-3...

  • Page 4: Introduction

    Questions? Call (315) 298-5121, or visit u.; online at 1vww. f ulton.com INTRODUCTION INTRODUC TION INSTALLATION OPERATION MAINTENANCE PARTS & WARRANTY - --...
  • Page 7 Placement & Rigging All information in this manual is for Proper placement of your Fulton Product (see Figures 1 and 2, and Tables 1 reference and guidance purposes, and 2) is essential. Attention paid to the following points will save a great deal and does not substitute for requlred of difficulty in the future.
  • Page 8 • NOTE: For UL listed units, see the specification plate on the Fulton Thermal Fluid Heater for these clearances. 3. Pipes must not be run within 1 O" (254 mm) of any control cabinets or combustible material.
  • Page 9 • NOTE: When calculating ventilation requirements, heat losses from the Fulton equipment (and other equipment) should be considered. Adhere to the following to meet ventilation and combustion air requirements: 1 . Install two fresh air openings, one at a low level, 24" (61 0 m m ) from the floor, and one at a higher level o n the equipment room wall.
  • Page 10 Recommended Stack Diameter Approximate Dry Weight 1,500 2,100 2,550 3,400 5,300 5,300 8,250 1 1 ,450 1 9,250 21,700 23,000 1,150 1,550 2,400 2,400 3.750 5,200 8,750 9,850 10,455 Questions? Call (315) 298-5 121, or visic us online at www.fulton.com...
  • Page 11 INSTALLATION SECTION 2 FTCS-IOM- 2 0 13-0227 3. Ensure the equipment room air supply openings are kept clear at all times. 4. See Table 5 for minimum make-up air req uired and the recommended area All information in this manual is for of each opening for each model.
  • Page 12 (e.g., as a result of construction and maintenance activities). i----- B ----1 FIGURE 2 DIMENSIONS (REFER TO T ABLE 2) Questions? Call (3 15) 298-5 12 1, or visit us online at www.fulton.com...
  • Page 13 FIGURE 3 - TYPICAL GAS-FIRED MODULATED CSD- 1 FUEL TRAIN Pilot Gas Valves 2" N.P.T. Gas Connection Regulator HI/LOW Gas Pressure Switch Gas Safety ShutoffValve __---- Manual Gas Regulator Butterfly Valve FIGURE 4 · TYPICAL GAS-FIRED MODULATED NFPA FUEL TRAIN The Fulton Companies 20 13...
  • Page 15 ° ° Propane gas pilot required. Oil must be delivered to the Fulton equipment at 16O F, 3 psi. Fulton in accordance with National Fuel equipment will then preheat the oil from 16O F to 23O'F.
  • Page 16 5. Determine multiple skid systems wiring requirements (between the skids). Fulton will run conduit and wire the devices on each skid. For the devices that have to come down for shipping, the wire will be left at the end of the conduit where possible and wired in the field (by others).
  • Page 17 Factors to be considered include efficiency, thermal stability, adaptability to various systems, and physical properties, including vapor pressure, freezing point, and flash and fire points. Heat transfer fluids of both mineral and synthetic origin have been specially The Fulton Companies 2013...
  • Page 18 Consider the following for selection: and strict adherence to applicable jurisdictional/ professional codes and 1 . The Fulton coil design heater is a fired heat exchanger and the safe regulations. control and monitoring of the thermal fluid temperature is of paramount importance.
  • Page 19 Fulton Thermal Corporation recommends that the thermal fluid in your system If excessive amounts of thermal fluid are vented from the system, be analyzed within the first two months after startup and annually thereafter.
  • Page 20 INSTALLATION SECTION 2 FTCS-/OM-20 13-0227 also result in thermal fl uid breakdown. Fulton heaters are equipped with a � WARNING temperature limit switch (located on the front of the panel box) to prevent this from occurring. All information in this...
  • Page 23 Non-Fulton product information is for reference purposes only. No Fulton • NOTE: Typical gaskets used by Fulton include JM Clipper Elastograph gaskets and document may substitute for full Flexitallic gaskets. Adhere to installation instructions and torque requirements for review of documentation available these gaskets.
  • Page 24 / professional codes and 1 1/4 regulations. 1 1/2 Non-Fulton product information is for reference purposes only. No Fulton 2 1/2 document may substitute for full review of documentation available...
  • Page 25 Number of Bolts Preferred Torque Req. (inches) (inches) Per Bolt (ft-lb) 1 1 /4 1 1 /2 1 00 2 1/2 1 00 1 00 1 00 1 00 1 60 24 5 1 60 The Fulton Companies 20 J 3...
  • Page 26 FTCS-IOM-2073-0227 Questions? Call /31 SJ 298-5121, or visit us online at www.fulton.com INSTALLATION SECTION 2 Insulation All information in this manual is for reference and guidance purposes, After the appropriate system tests have been satisfactorily completed and does not substitute for required...
  • Page 27 Fulton heater system. The pump See that pipe work connections match up accurately manufacturer's installation and operation instructions can be with pump flanges.
  • Page 28 FTCS-IOM-201 3-0227 Questions? Call ( 3 1 5) 298-5121, or visit us online at w1. ,w.fulton.com INSTALLATION SECTION 2 • The coupling alignment of the pump and driver must Grafoil packings require a run-in procedure. Typically, ■ be carefully checked for angular and axial alignment.
  • Page 29 SECTION 2 FTCS-IOM-20 13-0227 ■ Combination Deaerator/Thermal Buffer/Expansion Tank Fulton Thermal's efficient design combines the operation of the expansion, All information in this manual is for deaerator, and thermal buffer tanks. Installation is considerably simplified by reference and guidance purposes, virtue of this arrangement.
  • Page 30 FTCS-IOM-2013-0227 Questions? Call (315) 298-512 1, or visit us online at 1· '. 'V w.fulton.com 38 5 ,l INSTALLATION SECTION 2 1/2C N2 REGULATOR (50.8) - � I SAFETY RELIEF VALVECONN LIQUID ---- LEVEL - - - - - -...
  • Page 31 FT-500-L. Adhere to the following f o r installation: 1 . Install tank in accordance with Fulton Thermal Corporation's specifications. 2. Unless the system is pressurized, the inlet to the deaerator section must be higher than or equal to the highest point in the system to prevent pockets of air from collecting in system piping.
  • Page 32 3. If the tank is located outdoors, nitrogen is required. FIGURE 1 5 - LIQUID LEVEL SWITCH LOCATION Questions Call (31 SJ 298-512 1, or vi sic us online at IA , 1'!.fulton.com...
  • Page 33 1 1 . An inspection opening is located at the highest point on the tank. Access to this port is recommended but not required. 12. Refer to the maintenance schedule for recommendations on draining the buffer tank. For positioning of all connections on tank, see Figure 1 4. The Fulton Companies 2013...
  • Page 34 FTCS-IO. 'vl -2013-0227 FIGURE 17 GAUGES Questions Call /315) 298-5121, or visit us online at www.fulton.com INSTALLATION SECTION 2 ■ Catch Tank All information in this manual is for Adhere to the following for the catch tank: reference and guidance purposes, 1 .
  • Page 35 FTCS-IOM-2013-0227 The Fulton Companies 2013 INSTALLATION SECTION 2 withstand overpressure equal to the rating of the safety relief valves (normally 1 00 psig). Alf information in this manual is for reference and guidance purposes, ■ Thermometers and does not substitute for required professional training, conduct, °...
  • Page 36 ■ Automatic Fluid Control Valves All information in this manual is for Because of the widely varied processes in which Fulton Thermal Fluid Heaters reference and guidance purposes, are used, it is not possible to provide specific rules for the selection of automatic and does not substitute for required fluid control valves.
  • Page 37 Electrical wires are labeled for easy landing. professional training, conduct, Connect all wiring per the Fulton supplied electrical drawings. and strict adherence to applicable Jurisdictional/professional codes and 9. If a header is supplied, mount the header as shown in the mechanical regulations, drawing.
  • Page 38 Entrances Draft Regulator � Horizontal Run 2' 3 0i \ Cleanout \ Cleanout Door Door Cleanout Door FIGURE J S - TYPICAL STACK ANO FLUE INST ALLATION Questions? Co,: (3 151 298-5 121, or visit us online at v. ww.fulton.com...
  • Page 39 Check pressure ratings on all equipment in the system 2. Soap tests at all welds and joints to ensure that the to ensure that it is capable of withstanding the pressure system is free from leaks. involved. The Fulton Companies 2013...
  • Page 40 OPERATION INTRODUC TION INSTALLATION OPERATION MAINTENANCE - - - -- - PARTS & WARRANTY --- -- Questions' Coll (315! 298-5121, or visit us online at www.fulton.com...
  • Page 41 FTCS-/OM-20 7 3-0227 The Fulton Companies 20 7 3 OPERATION SECTION 3 Start-Up Preparation & Installation Review All information in this manual is for Review the installation section of this manual carefully. Confirm accordance with reference and guidance purposes, and does not substitute for required...
  • Page 42 FTCS-IOM-2013-0227 Questions? Call (315) 298-5121, or v:sit us onf'ne at www.fulton.com OPERATION SECTION 3 Fill the System Pressurizing a drum to force fluid into The viscosity of thermal fluid is generally very high (500 cS) at ambient the system is not recommended.

  • Page 43: Filling Procedure For Systems Equipped With Inert Blankets

    1 O. Determine the final nitrogen pressure by measuring the difference Non-Fulton product information ts for between the D.A. Tank inlet and the highest point in the system. Divide reference purposes only.

  • Page 44: Circulating Pump

    FTCS-IOM- 2 0 I3-02 2 7 Questions? Call (3 151 298-5121, or "isit us online at www.fulton.crm OPERATION SECTION 3 Circulating Pump � - WARNING 'r , - , All information in this manual is for Adhere to the following:...

  • Page 45: Pump With Packed Seal

    Where possible, contact the factory at least three weeks bef o re a Fulton service engineer is required on site. Before commission mg the unit, verify with proper authorities that gas lines Consider the following in preparation for your on-site visit: have been purged.

  • Page 46: Initial Start-Up

    OPERATION SECTION 3 FTCS-/O1\/-20 13-0227 Initial Start-Up All information in this manual is for These instructions are for use when the unit is being started up for the first reference and guidance purposes, time, or after prolonged shutdown. They are to be used in conjunction with the and does not substitute for required Routine Operation.
  • Page 47 (due to the use of a nitrogen blanket or large positive head). This always reset to their proper settings. should be noted and if the reading decreases by several inches or pressure, Contact your Fulton dealer before check the strainer to ensure it clean. modifying the equipment.
  • Page 48 Questions? Call (315) 298-5 12 1, or visit us online at 1, ww.fulton.com...
  • Page 49 Ignition and pilot are energized and a timed trial for (Units with Gas Pilot) pilot ignition begins. After the pilot flame is proven, ignition turns off and the main fuel valve is energized. Pilot fuel is turned off and the modulating motor The Fulton Compar:ies 2013...
  • Page 50 5. When the modulating motor (servo motor) is released to automatic, regulations. it receives its signal from the modulating temperature controller. The modulating motor (servo motor) then drives the modulating fuel valve and Non-Fulton product information is for air damper in proportion to the heat demand. reference purposes only.
  • Page 51 The fuel pressure gauge indicates the pressure of the fuel at the burner nozzle. Non-Fulton product information is for reference purposes only. No Fulton 8. Typical pressures range between 1 60-350 PSI ( 1 2-22 bar). Note the correct document may substitute for full setting upon commissioning.
  • Page 52 Non-Fulton product information is for reference purposes only_ No Fulton document may substitute for full review of documentation available fr o m the component manufacturer.

  • Page 53: Siemens Linkageless Modulation, Lmv 51

    A, press the left arrow key to get a). After you have pressed Enter on the last character of the password, press Enter once more to accept the password. If you do not have the password, contact your Fulton Authorized Representative to perform the changes. Service=NB# or OEM=AAAA (Enter after each A).
  • Page 54 Burner On by using the that "Burner On"is arrow keys. Press enter and verify acknowledged in the current field. Non-Fulton product information is for reference purposes only. No Fulton 1 1 . Press Escape twice t o get back t o the main menu.
  • Page 55 ON/OFF 6. Switch the switch back to The heater will re-start. 7. The light off point for main flame can be set at a higher input than low Non-Fulton product information is for fire. reference purposes only. No Fulton document may substitute for full Escape 8.
  • Page 56 FTCS-/OM-20 13-0227 Questions Call (31 SJ 298-5 121, or visit us anline at www.fulton.com OPERATION SECTION 3 8. Verify the flame signal on the display, measure input if gas meter is available. If not, match last elbow pressures and combustion for test fire sheet.
  • Page 57 FTCS-IOM-20 13-0227 The Fulton Compani<?S 2013 OPERATION SECTION 3 9. Once all the points have been verified, press Escape until you are back to the main menu. Do not operate, or allow others 10. You can observe the status of the burner by going to OperationalStat to operate, service or repair this >NormalOperation.

  • Page 58: Operating Controls

    FTCS-/OM-2013-0227 Questions Call (3 15) 298-5 121, or\ · s it us online at www.fulton.et m OPERATION SECTION 3 Operating Controls Do not operate, or allow others The following specifications, data, equipment and operating descriptions apply to operate, service or repair this to typical heaters.
  • Page 59 FTCS-IOM-2013-0227 _& 2. Reset motor starter; blower should start and purge cycle will begin. WARNING 3. Lockout of LMV will occur. Non-Fulton product information is for reference purposes only. No Fulton document may substitute for full ■ Pump Motor Starter review of documentation available from the component manufacturer.

  • Page 60: High And Low Fluid Pressure Switches

    FTCS-/OM-2013-0227 Questions? Call /315) 298-5121, or visit us online at www.fulton.com OPERATION SECTION 3 2. The heater is dependent on proper flow for operation; therefore, a differential pressure switch is used to sense the pressure drop across the heater. The differential pressure switch will shut the unit down in the event...

  • Page 61: Gas Pressure Switch

    FTCS-IOM-2013-0227 The Fu:ton Companies 2013 OPERATION SECTION 3 \J&· shuts down. Note the setpoint and lower by 1 0 PSI, then restart pump. The WARNING- · · •· · · •tq setpoint at cutout should correspond to the reading on the inlet pressure Do not operate, or allow others gauge.

  • Page 62: High Temperature Limit Switches Safety

    FTCS-IOM-2013-0227 Questions Call (3 1 SJ 298-5121. or visit us online at www.fulton.com OPERATION SECTION 3 monitoring of the thermal fluid temperature is of vital importance. The safe maximum temperature of the fluid must be strictly adhered to. Do not operate, or allow others 2.

  • Page 63: Operating Limit Controller

    OPERATION SECTION 3 4. Several consecutive lockouts caused by the high temperature limit controller indicate the need for immediate installation review. To ensure that your Fulton equipment is kept operating safely and ■ Operating Limit Controller efficiently, follow the maintenance procedures set forth in this manual.

  • Page 64: Test Of Ignition Safety System Shutoff

    FTCS-IOM-2013-0227 Q uestions 1 Call (315) 298-5121, or visit us online at wwv:.fulton.com OPERATION SECTION 3 pressure loss across the heater. The difference must not fall below the recommended value. Recommendations are based on heater size and are Do not operate, or allow others listed in manual and on the product data submittals on www.fulton.com.

  • Page 65: Required Pressure Drop Across The Heater

    2. At the recommended standard flow rates, and .7 sp gr, the pressure drop cross the heater should be as shown in Table 10. 3. In the event of an abnormal reading, contact Fulton Service immediately. Failure to take immediate action in the event of reduced fluid flow may result in rapid and serious degradation of the fluid, with possible damage to the heater.

  • Page 66: Procedure For First Shutdown

    5. Upon putting unit back into operation, check all gauge readings. Note any discrepancies and contact Fulton. Daily Start-Up 1. Check positioning of all system valves to ensure flow is not dead-headed.

  • Page 67: Daily Shutdown

    FTCS-/OM-2013-0227 The Fu/con Companies 2013 OPERATION SECTION 3 Daily Shutdown 1. Set control switch to "Pump" pump running, bu rner off. 2. Allow the fluid to circulate f o r approximately 20-30 minutes and then set the control switch to the "Off" position.

  • Page 69: Maintenance

    The log sheet is available from the Fulton Service Department, at the end of this section of this manual, and on www.fulton.com. What to do if you smell gas:...
  • Page 70 FIGURE 25- LINKAGE COMPONENTS All maintenance procedures should be completed by trained personnel . App1opnate training and instructions are available from the Fulton Service Department at (315) 298-5121 or your local Fulton Thermal Representative. In order to meet warranty conditions,...

  • Page 71: Weekly Maintenance Schedule

    Monthly Maintenance Schedule Appropnate training and instructions are available from the Fulton Service Depar tment at {315) 298-512 1 or your 1. Clean fuel filters. local Fulton Thermal Representative 2. Check burner blower. Clean if necessary.

  • Page 72: Semi-Annual Maintenance Schedule

    4. Take a one quart sample of thermal fluid and return to the thermal fluid activ1t1es are performed. manufacturer for analysis. 5. Schedule local Fulton representative or factory service technician to perform an annual preventative maintenance. General Maintenance Procedures ■ Lubrication Different motor manufacturers recommend various intervals for lubrication schedules.

  • Page 73: Soot Cleaning

    8. Fire the heater and set combustion. be completed by trained personnel. Appropriate tram mg and instructions Safety Check Procedures are available from the Fulton Service Department at (3 15) 298-5121 or your local Fulton Thermal Representative. Perform the following safety checks as needed: ■...

  • Page 74: Differential Pressure Switch

    FTCS-IOM-2013-022 7 FIGURE 30 - DIFFERENTIAL PRESSURE SWITCH Questions? Coll (315! 298-5 121, or visit us odine at 1.-1. :<fulton.com MAI NTENANCE SECTION 4 ■ Differential Pressure Switch With the circulating pump running, observe the difference in pressure between manual is All information in this the heater outlet gauge and the heater inlet gauge.

  • Page 75: Air Filter Box Switch

    Analog controls will open their contacts in the interlock Appropriate training and instructions circuit. Trip temperature should be within 5 degrees of PV temperature. Reset are available from the Fulton Service Department at (3 15) 298-5121 or your temperature limit if reset exists and reset flame programmer.
  • Page 77 2-stage, in which the 1st stage to light would be considered the pilot, or may have a gas pilot. In either case, during the pilot proving period, the flame programmer must sense a strong enough flame to initiate the opening of the main valves. The Fulton Companies 2013...
  • Page 78 If Fulton Thermal Corporation provided the heater skid, loss of head to the pump is extremely unlikely with proper fluid level in the combination tank. The most common low heater in a thermal piping system is water, which needs to be boiled out at startup or anytime new piping or fluid is added to the thermal oil system.
  • Page 81 It is important to make sure that the minimum flow rate as specified by Fulton for that specific model is maintained Check inlet and outlet pressures of the heater to determine differential pressure and flow rate. Ensure that this flow rate meets or exceeds minimums specified by Fulton (see chart).
  • Page 83 If the unit's refractory breaks, large enough pieces could block the flue passes. The burner should be pulled for refractory inspection. A broken refractory should be cleaned out and replaced. The Fulton Companies 2013...
  • Page 84 � Fulton Thermal Fluid Heater log Sheet g· "' Pump Heater Heater Inlet Heat.er Outlet Diff erenti1I Pump Suction Setpoint Current Nitrogen Pil0tFl1me Run Flame ·� stack Date Time Status Status Pressure Pressure Pressure Pressure Temperlf.JJre Temperature Level Sign11I Sign11I Temperature �...
  • Page 85 FTCS-/OA' -20 7 3-0227 The Fulton Companies 207 3 MAI NTENANCE SECTION 4...
  • Page 86 I NTRODUCTION INSTALLATION OPERATION MAI NTENANCE - - - -- - - - - - - PARTS & WARRANTY - - - - -- - Questions? Call (3 15) 298-5 121, or visit us online at w• · . r-.fulton.com...

  • Page 87: Parts

    Fulton Companies. When ordering replacement parts, please have recommended for this equipment. the model number and serial number of your Fulton boiler ready. Factor y -direct Use of non-factory authorized parts may jeopardize safety and system...

  • Page 88: Standard Warranty For Fulton Thermal Fluid Heaters

    PARTS WARRANTY Fulton will repair or replace F.O.B. factory any part of the equipment of our manufacture that is found to be defective in workmanship or material within one ( 1 ) year of shipment from the factory provided this equipment has been installed, operated...
  • Page 89 FTCS-IOM-2013·0227 The Fulton Companies 2013 PARTS & WARRANTY SECTION 5...
  • Page 91 Fulton Companies. Fulton Boiler Works, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of the Fulton Group of Companies, a global manufacturer of steam, hot water and thermal fluid heat transfer systems.

This manual is also suitable for:

Ft-s

Table of Contents