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Summary of Contents for FULTON ICW6 - 60 HP
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Page 1: Operation Manual
INSTALLATION AND OPERATION MANUAL Vertical Tubeless Design Gas/Oil-Fired Hot Water Boilers Model ICW 6 - 60 HP Serial/ National Board Number Model Fulton Order Sold To Job Name Date ICW-IOM-2012-1001... -
Page 3: Table Of Contents
HIGH LIMIT AQUASTAT/HIGH TEMPERATURE LIMIT ..............3 6 AIR SAFETY SWITCH ........................3 6 PROBE TYPE LOW WATER CUT OFF .....................3 6 Circulating Pump Switch ..................3-7 Cycle Testing ......................3-7 Before Leaving the Installation ................3-7 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 4 TABLE OF CONTENTS ICW-IOM-2012-1001 © The Fulton Companies 2012...
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Page 5: Introduction
INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 6: Overview
Code ANSI Z2231/NFPA 54 latest edition, and the speci c should it replace existing codes or standards which may be instructions in this manual. Authorities having jurisdiction applicable. Fulton reserves the right to change any part of should be consulted prior to installation. this installation, operation and maintenance manual. -
Page 7: Installation
INSTALLATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 8: Placement & Rigging
WARNING 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 required of di culty in the future. - Page 9 3150 *This dimension is 6 inches (152.4 mm) less for oil red units. Top View Side View Front View FIGURE 1 MODEL ICW DIMENSIONS/SPECIFICATIONS REFER TO TABLES 1 AND 2 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 10: Clearances & Serviceability
INSTALLATION SECTION 2 ICW-IOM-2012-1001 NOTE: When calculating ventilation requirements, heat losses from the Fulton WARNING equipment (and other equipment) should be considered. All information in this manual is for reference and guidance purposes, Clearances & Serviceability and does not substitute for required... - Page 11 Notes: Model sizes up to and including ICW30 have threaded inlet and outlet as shown on schema c. All larger sizes have fl anged inlet and outlet. Models ICW50 and ICW60 are provided with an extra plugged safety valve for extra relief capacity. For custom fuel trains, consult Factory for sizing and connec ons. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 12 Lifting Hook(s) Control Box Stainless Steel Ring (oil only) Flue Outlet Top Refractory High Density Insulation Water Return Outside Jacket Bottom Refractory Handhole Castable Refractory Insulation Boiler Runners FIGURE 2 COMPONENT VIEW OF THE ICW UNIT © The Fulton Companies 2012...
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Page 13: Utilities
(254 mm) of mercury at the pump inlet. Maximum inlet pressure to oil pump is 3 PSIG. 2. Make fuel connection in accordance with the details on the enclosed fuel Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 14: Electrical Supply
These may cause corrosion, deposition and/or fouling of equipment. To prevent these contaminants from impacting boiler performance, valve operation and general pipe longevity, each location must be analyzed and treated accordingly. Adhere to the following for water piping installation: © The Fulton Companies 2012... - Page 15 » Air removal equipment, including an air separator and automatic breather valves, along with a functioning expansion tank . Each must be designed to system speci cations. 11. When used in conjunction with a refrigeration system, install the boiler Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 16: Water Chemistry Requirements
Minimize system leaks to minimize make up water requirement Do not use open tanks or ttings Do not use oxygen permeable materials anywhere in the water system Repair leaks in the system quickly Eliminate ttings wherever possible 2-10 © The Fulton Companies 2012... -
Page 17: Eliminate System Air
40 or Schedule 80 as required by code and/or application; or copper if system parameters allow. 5. During construction of the installation, ensure that no dirt, water, or residue from welding is left in the system. 2-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 18: Insulation
Removable insulation may also be used over these components. System Interfaces Proper selection and installation of the components in the system will ensure proper and safe operation of the boiler. Consult Fulton representative or contact Fulton at (315) 298-5121. Fill Connection The system is usually lled from the lowest point, with the aid of a pump. -
Page 19: Pressure Gauges
1000 F (538 C) operating temperature. 2-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 20: Exhaust Side Wall Venting
11. An UL-approved Fulton factory-supplied draft fan must be installed to contraction, vibration, or other provide su cient draft (-0.02 to -0.04” wc) to safely vent products of movements. - Page 21 (45° Min.) Horizontal Horizontal Run 2' Run 2' 30° Cleanout Door Baffle Cleanout This Distance Door Must Not Exceed 25% Cleanout Of Total Rise Door FIGURE 3 TYPICAL STACK ARRANGEMENT 2-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 22 INSTALLATION SECTION 2 ICW-IOM-2012-1001 Side Wall Air Flow Side Wall Vent Vent Safety Switch (By Others) Termination (By Others) U.L. Approved Induced Draft Fan FIGURE 4 TYPICAL SIDEWALL VENTING 2-16 © The Fulton Companies 2012...
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Page 23: Operation
OPERATION INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 24: Start-Up Preparation & Installation Review
“Factory Trained Personnel” refers to This procedure ensures that all oils, sealants and other organic compounds are someone who has attended a Fulton Service solublized and removed from the boiler and piping. Consequently, if boil out is School speci cally for the equipment not accomplished prior to system operation, low water alarm, erratic water level covered in this manual. - Page 25 -purge valve, & all manual vents. Reset zone valves to normal mode of operation and turn o power to boiler. 12. Open fuel shuto valve, allowing fuel to ow to boiler. Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
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Page 26: Start-Up Service
Where possible, contact the factory at least and strict adherence to applicable three weeks before a Fulton service engineer is required on site. jurisdictional/professional codes and Consider the following in preparation for your on-site visit: regulations. -
Page 27: Flame Programmers
15 seconds, it will shut your Fulton dealer before modifying the down the burner. equipment. Flame Programmers Refer to inserts provided. Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 28: Operating Controls
The Low Water Cut-O shuts down the unit when the water level is too low, after a three-second time delay to prevent nuisance shut downs. Fulton boilers are equipped with ASME CSD-1 Code controls which include a manual reset feature on the burner low water cut o relay. -
Page 29: Circulating Pump Switch
2. Make sure the installation complies with all applicable codes. Never tamper with low water (liquid level) 3. Turn switch to OFF position. cuto sensors or circuitry. Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 30 OPERATION SECTION 3 ICW-IOM-2012-1001 © The Fulton Companies 2012...
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Page 31: Maintenance
MAINTENANCE INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 32: Daily Maintenance Schedule
Appropriate training and instructions The following steps should be carried out monthly: are available from the Fulton Service Department at (315) 298-5121 or your 1. Make sure main power switch is o before starting work. -
Page 33: Recommended Semi-Annual Maintenance Schedule
Never tighten more than necessary to prevent leakage. Excessive tightening may shorten the life of the gasket. FIGURE 5 REMOVE ASSEMBLY WITH TEE HANDLE WRENCH Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 34 All maintenance procedures should » Re ll the boiler with fresh water. be completed by trained personnel. Appropriate 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, ensure all appropriate maintenance activities are performed.
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Page 35: Recommended Annual Maintenance Schedule
Ensure primary air adjustment is adequate to avoid this condition. FIGURE 8 WIRE BRUSHING THE FLUE PASSAGES FIGURE 9 REMOVING CLEAN OUT PLUGS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 36: Procedure For Primary Air Adjustment/Inspection
2. Visually con rm, via the sight glass, that re is completely covering the After a new Fulton Boiler has been in walls. If the re is tunneling down or is not on the outside wall, e ciency operation for several months, pieces will drop. -
Page 37: Procedure For Flame Scanner Adjustment
Oil Unit Perform adjustment as follows: 1. Turn power to panel OFF. 2. Disconnect the hot wire to the oil valves. This will prevent the oil valves from opening. Questions? Call (315) 298-5121, or visit us online at www.fulton.com... -
Page 38: Procedure For Removing/Cleaning The Burner
4. Reverse removal steps for reinstallation of the burner assembly. 5. Test re the boiler and use a combustion analyzer to ensure that the fuel/ air ratio is set correctly throughout the range. Refer to the Fulton factory test re sheet for combustion settings. -
Page 39: Procedure For Soot Cleaning
2. Fire the boiler and perform combustion safety checks. 3. Analyze combustion throughout the range and verify proper operation of safety devices. Troubleshooting Please refer to Troubleshooting tables that follow. Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 40 If zero voltage, clean relay contacts and recheck for power. If no power, replace control. * For natural gas red boilers. Refer to the test re sheet for all other fuels. 4-10 © The Fulton Companies 2012...
- Page 41 -.04 in wc with burner o or -.04 in to -.06 in Draft when operating. May need to install a barometric damper. Make sure no exhaust fans are running in the Negative Room Pressure boiler room. 4-11 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 42 Refer to Recommended Daily Maintenance Scale Built up in boiler section of this manual. Check refractories to see if they are cracked or Refractories broken in pieces. Replace as necessary. Boiler Size Boiler may be undersized. 4-12 © The Fulton Companies 2012...
- Page 43 Check all lines for possible air leak in intake line Loss of oil prime and tighten. Check for possible restricted intake line. Replace. Oil Nozzle Check for clogged nozzle; clean or replace 4-13 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 44 Draft -0.04 to -0.06 when operating. May need to install barometric damper. Check all lines for possible air leak in intake line Loss of Prime and tighten. Check for possible restricted intake line. Replace. 4-14 © The Fulton Companies 2012...
- Page 45 Check for slipping or broken coupling. Oil Pump Tighten or replace. Check for frozen pump shaft. Replace. If power is on, check across aquastats to verify Aquastat power through switch. If bad, replace. 4-15 Questions? Call (315) 298-5121, or visit us online at www.fulton.com...
- Page 46 MAINTENANCE SECTION 4 ICW-IOM-2012-1001 4-16 © The Fulton Companies 2012...
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Page 47: Warranty & Parts
WARRANTY & PARTS INTRODUCTION INSTALLATION OPERATION MAINTENANCE WARRANTY & PARTS Questions? Call (315) 298-5121, or visit us online at www.fulton.com... - Page 48 WARRANTY & PARTS SECTION 5 ICW-IOM-2012-1001 © The Fulton Companies 2012...
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Page 49: Standard Warranty For Fulton Boilers
fi tness for a particular purpose. Fulton shall in no event be liable for any consequential or incidental damages arising in any way, including but not limited to any loss of profi ts or business, even if the Fulton Companies has been advised of the possibility of such damages. -
Page 50: Parts
Fulton Companies. When ordering replacement parts, please have for this equipment. Use of non-factory the model number and serial number of your Fulton boiler ready. Factory-direct authorized parts may jeopardize safety replacement parts must be used to ensure proper equipment operation and and system performance, and voids the adherance with warranty requirements. - Page 52 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 uid heat transfer systems.
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