Fulton Edge ICX or FB-F Vertical Tubeless Boilers (Steam) Bedienungsanleitung

Instruction, Operation, and MaintenanceManualFulton Gas Fired SteamBoilers  HP to 60 HPSerial Number: _______________________________Model Number:

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Component Data Sheets7-G 1/01

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5-G 1/01Safety Warnings/PrecautionsSafety Warnings Cautions &NotesThe following WARNINGS, CAUTIONS, and NOTES appear in various chapters of thi

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7-G 1/01Description/InstructionsLE

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Standard Models ICS/FB-A 9.5 10 15 20 25 30Models ICX/FB-F 9.5 10 15 20 30Unit Size: BHP 9.5 10 15 20 25 30A. Boiler Height IN 67.5 63.5 69 72.5 74.5

SpecificationsModels ICS/ICX/FB 9.5 10 15 20 25 30Boiler ConnectionsN. Steam Outlet 15 PSI N/A 1.5” 2” 3” 3” 3”NPT NPT CL150# CL150# CL150#Flange Fla

11-G 1/01OperationLE

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13-G 1/01Starting the Gas Fired BoilerSee page 44-GGas Burner Set Upa. Open the manual gas cocks onthe pilot and main lines of the gashead.b. Switch

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15-G 1/01MaintenanceLE

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17-G 1/01Pilot Adjustment for FultonLoNOx Burner.a. Close downstream main shut offvalve.b. Start boiler and check flame sig-nal on pilot, lock prog

18-G 1/01Troubleshootinga. The following troubleshootingguide will assist in the diagnosis andthe correction of minor field prob-lems. It contains

19-G 1/01Problem Cause RemedyFlame Failure 5. Scanner Check for dirt on flame scanner and clean. Check for proper location of detector.6. Flame Sa

20-G 1/01Problem Cause RemedyPoor Combustion 1. Refractories Check refractories to see if they are plugged with soot or broken in pieces. Clean or

21-G 1/01Problem Cause RemedyBoiler is Surging 1. Steam traps blowing Check traps to see if they are clean or replace as necessary.through2. Perc (

22-G 1/01Problem Cause RemedyWater pump will not 1. Scale on probes Check and clean or replace as necessary.come on at times2. Bad Pump Contactor C

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ProductBulletinProduct Bulletin2010-001PBThe Fulton Companies972 Centerville RoadPulaski, N.Y. 13142Date: January 22, 2010Subject: Water Chemistry Req

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25-G 1/01Spare Partsa. It is important that the correctreplacement part is fitted to yourFulton Gas Fired Steam Boiler.b. When ordering replacement

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Boiler Description/Instructions Gas Fired Boiler227-G 1/01

Description/InstructionsTransformer ScrollGasketsSteam GaugeAssemblyGauge GlassValveTo O.P.C.*To H.P.C.*Burner MotorGauge GlassValveGauge GlassA

BIJON/OFF GAS HEADCAN PIVOT 360°MODULATED GAS HEAD ISFIXED ABOVE FAN HOUSINGCLEARANCE REQUIRED FORBURNER REMOVALETop ViewFront ViewSide ViewKPNFAMSHRQ

ffsstd-pds-2011-1222SpecificationsModels ICS/ICX/FB 4 6 9.5 10 15 20 25 30 50 60Boiler ConnectionsN. Steam Outlet 15 PSI 1” 1” N/A 1.5” 2” 3” 3” 3” 4

30-G 1/01Description/InstructionsIEKKJKDCHBAGF

Description/InstructionsLocating the Boilera) The boiler should be located in drysurroundings on a level base, makingsure that there is sufficient ro

32-G 1/01Description/InstructionsVentVentReturnCold WaterSupplySightGlassUnionPump/StrainerThermometerAquastatDrainCondensateReturnTankBlowdownSepara

Description/InstructionsSafetyValveWaterColumn andSightGlassElectricControlPanelGas FiredSteam BoilerShutOffValveCheckValvesFastOpeningValveBlowdownVa

Description/InstructionsBoiler Installation The Steam Supply — Pipe thesteam supply line from the top rightside of the boiler. The Steam Safety Valv

The Blow-Off Valve — There are twoblow off valves on the boiler: Themain valve at the rear of the boilerand the water gauge glass blow offvalve. The

36-G 1/01Water Gauge & Gauge GlassInstallation instructionsNOTEOnly properly trained personnelshould install and maintain watergauge glass and co

Water Supplya) Feed water contains solids anddissolved gases. These may promoteincrustation of scale; foaming, prim-ing, surging, and solids in steam

38-G 1/01pH: pH is a measure of the degreeof acid or base of solution. NormalpH ranges of 6.5-9.0 will have littleinfluence on the corrosion rate ofc

39-G 1/01Electrical Requirementsa) Connect wiring as shown in the wiring diagram which is furnishedinside the electrical control panel box.b) Be sur

40-G 1/01Conventional Ventinga) The stack should rise continuouslyto the connection with the chimney,and should contain no more than twobends at 45 a

41-G 1/01Description/InstructionsExhaust Side Wall Venting (UL andMEA Approved- MEA File Number68-79-E Vol. 2 ) a) Boilers for which sidewall ventin

42a-G 1/01Installation Check Points1) Make sure all piping connectionsare complete and tight.2) Make sure the pressure controlsare adjusted properly

IntroductionThis manual is provided as a guideto the correct operation and mainte-nance of your Fulton Gas FiredSteam Boiler, and should be perma-nent

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43D-G 1/01Operation3

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44-G 0/01Starting the Gas Fired Boiler Stop! Make sure you have readand followed all previous safetyinformation.Check with local authorities whereap

OperationGas Burner Set UpNOTE: Refer to Section LE for LOW EMISSIONS BURNERSa) Open the manual gas cocks on thepilot and main lines of the gas head.

46-G 0/01OperationGas Burner Set Up For BoilersEquipped with Modulationa) Modulation is available as anoption on Fulton gas fired steam boil-ers for

47-G 1/01OperationGas Burner Set Up For BoilersEquipped with High-Low-Offa) A gas fired burner equipped forhigh-low-off firing is available as anopt

48-G 0/01OperationWARNINGPrior to the commencement of anywork requiring the removal ofcover plates and the opening of thecontrol panel box, the elect

49-G 1/01OperationBoiler Controls a) Flame safeguard burner control–This is the main control in the panelbox. The programmer in conjunctionwith a s

Maintenance45-G 1/01

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Transformer ScrollGasketsSteam GaugeAssemblyGauge GlassValveTo O.P.C.*To H.P.C.*Burner MotorGauge GlassValveGauge GlassAnd ProtectorWater Column

MaintenanceNOTETo ensure the continued safety andefficiency of the boiler, the sched-ule of maintenance outlined in thissection should be adhered to.W

PrimaryAir GateBurnerViewing PortBlast TubeViewing PortBlast TubeScanner (4–15 HP)FlameRod(s)*Gas HeadScanner Location(20–60 HP)BurnerPlateAir Deflect

Furnace Refractory ReplacementProcedure a) Remove the burner plate and topplate assembly up and out of the scrollassembly.b) Remove the stainless st

56-G 1/01Recommended DailyMaintenance Schedulea) The following procedures should becarried out daily. They are designed toprevent the build up of s

57-G 1/01Maintenanceg) Remove brass pipe plug at thecross connection below water columnand clean nipple into boiler. Boilermust be cold and water le

g) Replace hand hole gasketsusing the following procedure:1) Remove the hand hole assemblyusing a 1-1/4" tee handle wrench or 1-1/4" 1/2&q

59-G 1/01MaintenanceTroubleshootinga) The following trouble shootingguide will assist in the diagnosis andthe correction of minor field prob-lems. I

60-G 1/01Problem Cause RemedyFlame Failure 5. Flame Rod Adjustment Check flame rod for carbon buildup and clean ifor UV Scanner necessary. Check fl

1-G 1/01ContentsSection Safety Warnings & PrecautionsFor Boilers with Low Emissions Burner OnlyDescription/InstructionsSpecifications & D

61-G 1/01MaintenanceProblem Cause RemedyPoor Combustion 1. Refractories Check refractories to see if they are plugged with soot orbroken in pieces.

62-G 1/01MaintenanceProblem Cause RemedyBoiler will not 4. Scale Built up in boiler Refer to Section 2 “Pressure Vessel Cleaning”.maintain pressure5

63-G 1/01MaintenanceProblem Cause RemedyPump runs but does 1. Vapor locking of pump. Allow system to cool down, check steam trapsnot put water into

Parts56-G 1/01

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66-G 1/01PartsSpare Partsa) It is important that the correctreplacement part is fitted to yourFulton Gas Fired Steam Boiler.b) When ordering replacem

Parts5-60-100 Instruction Manual, Fuel-Fired 2 0.915-60-165 Certification Papers5-60-164 Boiler Documentation for Export BoilersBoiler Shell Parts5-1

Parts5-21-302 Steel Jacket 10 HP - No Holes Cut 100 45.455-21-303 Steel Jacket 15 HP - No Holes Cut 115 52.275-21-304 Steel Jacket 20 HP - No Holes C

PartsBurner Assembly - Parts (Common)2-40-605 1/3 HP 115/230/60/1 Burner Motor 3450 RPM 21 9.552-40-606 1/3 HP 230/460/60/3 Burner Motor 3450 RPM 20

Parts2-30-118 Air Switch 4-100 HP 0.72 0.335-20-019 Burner Plate Gas - 4 HP 1 0.455-20-007 Burner Plate Gas - 6 & 10 HP 1 0.455-20-055 Burner Plat

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Parts2-30-102 1/2" Gas Pressure Regulator RV 48 0.7 0.322-30-104 1" Gas Pressure Regulator - RV 53 1.5 0.682-30-105 1-1/4 " Gas Pressur

Parts7-30-025 Burner Plate Assembly - 4 HP - Natural Gas 7 3.187-30-026 Burner Plate Assembly - 6 HP - Natural Gas 8 3.647-30-123 Burner Plate Assembl

Parts2-12-018 10" Water Gauge Glass- MM 0.06 0.032-12-071 12" Water Gauge Glass 0.07 0.032-12-063 14"Water Gauge Glass 0.08 0.042-30-15

Parts2-45-106 Green Panel Box Indicating Light - 120V 0.1 0.052-45-107 White Panel Box Indicating Light -120V 0.1 0.052-45-108 Amber Panel Box Indic

Parts2-40-161 Mini Peeper For All 7800 0.5 0.232-40-270 Base For All 7800 0.5 0.232-40-272 Display Module for 7800 Controls English (Also Available i

Parts2-30-068 3/4"-100# Safety Valve 2 0.912-30-069 3/4"-125# Safety Valve 2 0.912-30-070 3/4"-150# Safety Valve 1.4 0.642-30-071 3/4

Parts5-10-397 Tee Handle Wrench 2.7 1.232-20-110 Fan Puller - 5/8" Hub 2 0.912-20-115 Fan Puller - 1" Hub 2 0.91Barometric Controls2-30-0

Parts2-12-528 Scroll Gasket - 4 HP 1 0.452-12-529 Scroll Gasket - 6-15 HP 1 0.452-12-530 Scroll Gasket- 20-30 HP 1 0.452-12-531 Scroll Gasket- 40-60 H

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80-G 1/01PartsPart No.* Burner Motor (1)RPM HP2-40-605 1/3 HP 115/230/60/1 3450 4-152-40-606 1/3 HP 230/460/60/3 3450 4-152-40-603 1/3 HP 110/2

Safety Warnings/Precautions13-G 1/01

81-G 1/01PartsGas BurnerIgnition AssemblyGas Burner Components

82-G 1/01PartsGas Head AssembliesPart No. Complete Gas Head Assembly HP7-54-1000 Natural Gas 47-54-1001 Natural Gas 67-54-1002 Natural Gas 107-54-10

83-G 1/01Parts1291011683254768910111Gas Head Assembly (CSD-1)4 to 50 HPGas Head Assembly (CSD-1)60 HP

84-G 1/01PartsWater LevelRelayContactor/Overload–3 Phase (Upon Request) orStarter Relay–1 PhaseFor Feed WaterPump MotorFlameSafe Guard/Burner Control

85-G 1/01Parts1412(LocatedInBoiler)913111012615845373Water Column - Parts Part No. Water Column Bottle Casting (1) HP5-20-022 Water Column Bottle Ca

Warranty68-G 1/01

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Standard Warranty for Fulton Boilers Warranty Valid for Models ICS, ICX, ICW, ICXW, VMP, VMPW, FB-A, FB-F, FB-L, FB-S, FB-W Five (5) Year (60 Mont

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Extended Warranty for Fulton Skid Mounted Steam Boilers Warranty Valid for Models ICS, ICX, VMP, FB-A, FB-F, FB-L, FB-S Ten (10) Year Material and W