FBC/FBD Fulton Horizontal Boilers

BOILER : F1045174A MODEL: FBC-300-4P LBS STEAM PER HOUR: 10,332 SHELL: 0.550" HEAD: 0.7874" YEAR: 2011

Safety Precautions To Owners, Operators or Maintenance Personnel: It Is essential to read and understand the following safety precautions before attempting to operate or service this equipment: Failure to heed these precautions may result in damage to equipment, serious personal injury or death! 1. The equipment should be operated only by personnel who have a working knowledge and understanding of the equipment. 2. A complete understanding of this equipment’s operational manual is required before attempting to startup, operate or maintain the equipment。 3. Disconnect and lockout the main power supply in order to avoid the hazard of electrical shock. 4. Do not repeat unsuccessful lighting attempts without rechecking the burner and pilot adjustments. 5. The cause for loss of flame or any other unusual condition should be investigated and corrected before attempting to restart. 6. Should a starting failure occur for any reason, combustible fumes may fill the combustion chamber. Never attempt to re-light the burner under these conditions without first purging. 7. Do not re-light the pilot or attempt to start the main burner, either oil or gas, if the combustion chamber is hot and/or if gas or oil vapor combustion gases are present in the furnace or flue passages or when excess oil has accumulated. Promptly correct any conditions causing leakage. 8. When switching the fuel in dual fuel burner, stop the boiler first. Do not attempt to start the boiler when the combustion chamber is still hot. 9. Do not disassemble, maintain or change any boiler pressure parts when the boiler and its connecting piping is under pressure or hot. 10. When a leakage is found in gas piping (especially LPG gas), do not attempt to start, maintain or repair the boiler before correct the problem and confirmed by the local gas company. 11. When light the boiler, any person should stay away from the boiler. Standing in front and near the front and rear smoking chamber and burner is strictly restricted. Thank for choosing Fulton boilers! Fulton China 2011-1-13

Introduction Regular inspection should be carried out by competent personnel with interval between two inspections no more than 14 months. The range and actual interval is decided by the competent personnel as detail. The operator should have been qualified with certificate and operate the boiler per corresponding regulations.

This manual presents information that will help to properly operate and care for your Fulton boiler, and the requirement should be followed in maintenance. These instructions must not be considered as a complete code of practice, nor should they replace existing codes or standards which may be applicable.

Follow the requirement, otherwise boiler damage or serious personnel injury may result.

Although every operation and control equipment may work reliably for a long time, necessary test should be done to avoid damage to equipment or personal injury or death.

Warnings The installer should ensure proper and safe connections that all the accessories to the boiler.

It is recommended that the daily, weekly, monthly and semi-annually, annually maintenance, and any abnormal status should all be recorded carefully so that service technician can easily determine and solve the problem.

Do not attempt to maintain your Fulton boiler without corresponding knowledge. Consult us in time for the related technique support.

The requirements and instructions contained in these sections are mainly for the standard Fulton boiler model FBC/FBD. When installing a packaged unit, read entire sections to ensure that the installation is carried out correctly.

Fully understand the circuit prior to wire or remove one electric component. Wrong wiring may result severe situation. Do not operate boiler while status like trouble sets forth or part(s) is (are) lost, otherwise personnel injury or death may result. Ensure all the steps of maintenance are carried out before operation.

Prior to shipment the following tests are made to assure the customer the highest standards of manufacturing: a) Material inspections. b) Manufacturing process inspections c) Welding inspection. d) Hydrostatic test inspection. e) Electrical components inspection. f) Operating test. g) Final engineering inspection. h) Crating inspection.

Please follow the local regulations. Do not change fuel without written agreement from Fulton. Consult Fulton for reinstallation engineer of Fulton will arrange this.

The customer should examine the boiler for any damage, especially the refractory. Fulton boiler is constructed in accordance with Technical Supervision Regulation for Safety of Steam Boiler or ASME code.

and

the

Do not operate boiler overload due to boiler damage or dangerous situation.

1

Content 1 Description General Specification

2 Installation General Locating the boiler Vent Flue Outlet Water Supply Valves & Gauges Electric Requirement Gas Supply Oil Supply Check after Installation Boil Out for New

3 Control System & Burner Controls Flame Programmer-RM7800 Relay Module Boiler Pressure Control Boiler Temperature Control IC-S/D Burner

4 Boiler/Burner Operation Start up Boiler Shut Down Boiler Joint Inspection Burner Operation

5 Maintenance Regular Check Recommend Daily Maintenance Recommend Week Maintenance Recommend Semi-Annual Maintenance Recommend Annual Maintenance Fitting New Gasket Burner Maintenance Common Gas Line Maintenance Flow Chart

6 Trouble shooting Trouble shooting Honeywell RM7800 Trouble shooting

7 Guarantees 2

SECTION 1 DESCRIPTION General

Fulton FBC/FBD series is a kind of horizontal, three or four pass wet back boiler constructed in accordance with ASME and/or Chinese code. In which FBC series are steam boilers while FBD series are hot water boilers. The packaged boiler is consisted of pressure vessel, burner, burner controls and appropriate boiler trims. Each boiler has been strictly inspected to guarantee the highest standards. However, high performance is achieved by following this manual at the aspect of installation, operation and maintenance. Smoke boxes are mounted at front and rear of the boiler for convenience of cleaning the combustion chamber. There is a manhole at the top of boiler, while hand holes are located at side bottom, front and rear of the boiler for PV check. The following are standard fittings and accessories: Steam boiler 1 Main Steam Valve 2 Safety Valve 3 Blow Down Valve 4 Surface Blow Down 2

5 Water Gauge Assembly 6 Steam Pressure Gauge Assembly 7 Water Feed Valve & Check Valve 8 Water & Steam Pressure Control Hot Water Boiler 1 Main Water Supply Valve (optional) 2 Return Water Valve (optional) 3 Safety Valve 4 Exhaust Valve 5 Blow Down Valve 6 Low Water Protect 7 Temperature Protect and Control 8 Limit Temperature Interlock

4

Specification FB-C Boiler Specification

Note：1. The above feed water pump is the standard Fulton pump, other please consult factory. 2.All steam output rating from 0PSI at 212oF, fuel consumption based on light oil 20,160 Btu/lb (11200 KCal/kg), heavy oil 19728 Btu/lb (10960KCal/kg), natural gas 1,000 Btu/ft3 (8900KCal/m3). 3. Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. the factory’s most current drawings.

5

Please refer to

FB-C Boiler Exterior Dimension

Note: 1. The above number is based on light oil burner. 2. Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. Please refer to the factory’s most current drawings.

FB-C Boiler Connection

Note: 1.Electric requirement is based on the standard fittings. 2.Shipping weight doesn’t include the burner system. 3.Specifications and Dimensions are for your reference only. The Fulton Companies reserve the right to change dimensions and/or specifications. factory’s most current drawings.

6

Please refer to the

SECTION 2 INSTALLATION General and local regulations.

Only proper and trained personnel should install Fulton FBC/FBD boiler, and the installation should comply with all the relative safety specifications and local regulations.

b. Sufficient space around the boiler should be available in the boiler room for ease access to all the boiler parts for boiler operation and maintenance.

Locating the boiler

c. The boiler should be placed on a level floor with firm base and without combustible articles surrounded.

a. The boiler room should be arranged in accordance with the relative safety specifications

Fig. 2-1 Boiler room Lay Out (Reference)

9

Vent b. Provide both high and low level openings per burner power for safe and efficient boiler operation.

a. Proper ventilation of the boiler room is essential. It requires one opening of fresh air for 6.4cm2 for every 756 Kcal. Table 2-1 Recommended Min. Air Opening Model FB-C 2

Minimum area (m )

300

350

400

500

650

800

1000

1300

3.1

3.6

4.2

4.8

6.2

7.2

9.1

12.4

Flue Outlet The height and type of flue will be subject to local specifications. Where a flue is required by multi-boiler are necessary, ensure the common section meets the requirement that all boilers can work at the same time, and special design must be obtained.

horizontal runs. The total horizontal runs should not exceed 25% of the vertical rise. All horizontal runs should have a rising pitch of 15o minimum to lower resistance and prevent condensate from building up and subsequent corrosion.

a. The diameter of chimney must be not less than that of flue outlet; otherwise the increased gas resistance would affect combustion.

d. Oil-fired boiler installation is generally more critical because of the sulphur content in the fuel and the dew-point temperature. Specialist advice should be obtained on flue and insulation.

b. Usual chimney arrangement supply -0.02~-0.04” w.c. pressure. However, the pressure should not be too much. Install regulator at the flue outlet while the pressure is too much due to construction etc.

e. Flue outlet should higher than all the roofs around the radius of 10m. f. Check boiler smoke outlet, flue and each joint of chimney for sealing.

c. Avoid fitting 90o elbows and long distance

10

11

Fig. 2-2

Chimney Arrangement

Water Supply a. Feed water contains solids and dissolved gases. High dissolved oxygen and chloride levels, low PH and high water hardness can all be major causes of corrosion and deposition. These may influence boiler life. So, water treatment is necessary.

the dissolved oxygen is to heat feed water to let air escape. Inject steam into the water to raise the temperature to 82oC so that the dissolved oxygen is removed from the water. It is recommended to install oxygen removing equipment.

b. Fit water softener equipment while water hardness is high.

d. Feed water should be studied individually and treated accordingly by reputable professionals in this field. It is highly recommended that a water treatment specialist is consulted prior to install the boiler.

c. The dissolved oxygen can cause corrosion in boiler plate and water supply system, with many pits. These little pits gradually change into larger ones and usually covered by ferric oxide. Once the corrosion sets forth, the speed will be rapid without reverse. One way to reduce

e. The Fulton Warranty does not cover damage or failure that can be attributed to corrosion, scale or dirt accumulations. Oxygen is corrosive.

Table 2-3 Water Requirement Item

Feed Water ＞1.0

＞1.6

≤1.6

≤2.5

≤5

≤5

≤5

≤0.03

≤0.03

—

PH（25℃） Dissolved Oxygen mg L3

Boiler Water ＞1.0

＞1.6

≤1.6

≤2.5

—

—

—

≤0.03

~

~

~

—

—

—

≤14

≤12

≥7

≥7

≥7

10~12

10~12

10~12

≤0.1

≤0.1

≤0.05

—

—

—

—

—

—

＜4000

＜3500

＜3000

—

—

—

—

＜3000

＜2500

mg/L

—

—

—

—

10-30

10-30

PO43-, mg/L

—

—

—

—

10-30

10-30

Relative Alkalinity(Free NaOH /Dissolved 5 solids）

—

—

—

—

＜0.2

＜0.2

Oxygen mg/L

≤2

≤2

≤2

—

—

—

Fe mg/L6

≤0.3

≤0.3

≤0.3

—

—

—

Rated Capacity Mpa

≤1.0

Suspend solids mg/L 1

Total Hardness mmol/L

2

Total Hardness mmol/L

W/O Superheater W/ Superheater

W/O 4

Dissolved Solids mg L

Superheater W/ Superheater

So32-,

≤1.0

a. It is recommended that blow down every day to avoid corrosion and scale inside because of the solids and concentrate salt deposit in the boiler. b. It is recommended to heat feed water in case of no condensation water.

13

Valves & Gauges

Water Gauge Assembly

The boiler pressure fitting is mounted at the upper right side, with one three way cock faucet downstream the pressure gauge for periodical blow down.

FBC steam boiler is fitted with two plate water gauge assemblies. The water gauge blow down valve is connected to the auxiliary blow down line by 1/4”soft copper tubing.

Main steam Valve/Water Supply Valve

Water Sample Valve (Surface blow down)

Distribution pipeline should be run from the main steam valve or water supply valve on top of the boiler to the steam or hot water delivery point. Adequate condensate drainage and expansion facilities are provided with the pipeline. Securely support the valve to avoid excessive load.

The standard fitting is at the right side of the boiler that makes water sample to control boiler water. Water Feed Valve/Check Valve The Water feed valve is connected to the water inlet which at middle right side of boiler. The check valve is fitted at the end of the line of water feed valve to prevent return water.

Blow Down Valve

Return Water Valve

The boiler is fitted with two or three blow down valves. One is at each water gauge and the main at the side of front and rear of the boiler. Pipeline from these valves must be connected to a receptacle of approved with all process follow the local regulations.

Installed at the top return water inlet for system hot return water using.

Electrical Requirement The boiler wiring diagram is located on the inside of the boiler control panel.

Safety Valves The safety valve is factory fitted at the top of boiler and preset. Do not adjust without permitting from authority and Fulton.

A 3-phase 5 wire supply is required; the power is 380V/50HZ/3phase. Voltage limit: high and low 10%.

a. The Fit pressure is indicated on the valve. Do not adjust without permitting from authority and Fulton.

Caution: all electrical work should be undertaken by a qualified installer according to local regulations.

b. This valve is designed to prevent the boiler from exceeding its design pressure.

Gas Supply Natural gas is the standard for the gas boiler. If special requirements i.e. liquid petroleum gas, town gas or others are used, consult Fulton prior to use.

c. Any system connected to the boiler which is not capable of accepting boiler pressure must be protected by a separate safety valve setting to the required pressure.

The gas pressure varies with different burner models and burner head. Outer pipeline should be greater one to keep enough operation gas pressure (dynamic).Verify if the gas pressure meets the requirement of the burner, install one gas booster in case of too low pressure. Any question please consults FULTON

d. It is recommended to fit the discharge pipe with size equal or more than safety valve outlet. The discharge pipe should be capable of strength bearing, and as short as possible. The discharge outlet should be piped to a safe discharge point and the condensate will drain away easily. (Do not connect blow down pipe).

When a gas booster is used, the gas pressure at the booster inlet must not fall below 1000 mm W.C.. The booster should be installed as near as

Caution: The factory-fitted safety valve is designed to protect only the boiler. This valve must not be used to protect other items. 14

possible to the burner. It should be positioned on a firm, flat, horizontal surface using anti-vibration mountings. All connecting pipework should be well supported and accurately positioned in order to avoid stressing the booster casting. The use of flexible connections, which reduce both pipework stresses and transmitted noise, is strongly recommended. The gas supplier should be asked to recommend the size of pipework between the meter and the booster to ensure that the required pressure and flow are available.

NOTE: It is essential that a manual isolation valve is fitted upstream of the gas control train to allow the burner to be isolated for maintenance. The size of this valve should not be less than that of the burner control train in order to avoid any restriction in gas flow. WARNING: It is essential that the installation of the gas pipework must be undertaken only by suitably qualified and experienced personnel and in compliance with appropriate Codes and Standards.

To minmize gas pressure drops, eliminate all unnecessary elbows and bends between gas meter and head. Install one correct size gas valve as close as possible to the head.

Oil Supply

One butterfly gas stop valve with interlock switch is mounted on the dual burner. The switch should be connected to the interlock terminal inside the control panel.

Oil–fired boilers are supplied with a matched automatic modulating oil burner suitable for use of light diesel oil. The oil is 0# with storage temperature not less than 5oC and heat is required for heavy oil to obtain good flow. Other fuels consult Fulton. The pipework should be seamless steel tube, zincification is not permitted. Heavy Oil supply requires heater and the oil storage tank as well. The recommended heat Temp. is as follows:

The gas supply pipework to the boiler must be appropriate to local conditions and must be constructed and installed in compliance with appropriate Codes and Standards, and must be undertaken by qualified professional personnel.

Table 2-4 recommended heat Temp. Item

Oil

Oil Tank Heat Temperature

Burner Electrical Heat Temperature

1

20#-60#

40℃-60℃

50℃-70℃

2

80#-120#

50℃-70℃

60℃-80℃

3

180#

60℃-80℃

70℃-90℃

4

200#

70℃-90℃

80℃-100℃

5

220#

80℃-100℃

90℃-110℃

6

250#

90℃-110℃

100℃-120℃

Two-pipe System

An oil filter must be installed before the oil

A two-pipe system must be used between oil storage tank and the burner. One for oil supply and one for oil return. A circulating oil pump is required to deliver fuel oil from the storage tank to the burner. Circulation pressure is 15psi while 50-70 psi is for FBC1300 models and above.

circulating pump, recommend below 2t/h more than 80 mesh/inch2 and above 2t/h more than 60 Mesh. Use flexible pipework for the final oil connections 15

to the oil pump (stainless steel corrugation tube). Ensure no twist generates and the sealing is good.

It is important to ensure that the return pipe is not obstructed or closed suddenly, install stop valve as little as possible.

One stop valve should be installed at the inlet and outlet of the circulating pump separately. A pressure gauge (0-60psi) is needed also to the outlet.

In case of heavy oil 4#, 5#, and 6# oil (heavy oil 80#~250#) the pipework and oil storage tank should be with heater. Fig 2-3 Two Pipe System

Oil supply pipework use DN50 seamless steel tube to reduce pressure loss.

Check after Installation Check for all pipework connection, remove dirt in pipework and check for leakage. Check for pressure control. Check for control panel and other circuit connection per requirement. Impurity among combustion air would damage the steel jacket and firetube if the door of boiler room is closed. Note : After complete the installation, Clean the PV prior to operation.

Boil out for New

c. Install one overflow pipe at any opening on top of the boiler and discharge to safe place.

Clean the pressure vessel of any oil film, dirt, or other impurities that set forth in the process of production to avoid heat efficiency loss. Boil out a new boiler is one of the cleaning methods. Boiler installation unit should know the method and may be the agent to do this.

d. Remove the safety valve to avoid oil adhering to it. e. Close all the valves connected to the system to prevent detergent entering into system. f. Pour clean water up to top end of water feed pipe. Fill the above solution into the boiler. The water temperature should be the same as ambient.

Many chemical medicines may be used for boiler out, usually apply mixture of trisodium phosphate and sodium hydroxide with water with percentage 0.3%~0.5%, and add a little wash detergent too.

g. Heat the boiler with low fire to keep boiler water boiling. The time of boil out should be no less than 5 hours with no steam pressure generating.

Recommended steps: a. Prepare chemical medicine.

h. At this moment, fill the boiler with a little water to bring away the impurities via overflow.

b. Prior to dissolve the medicine, pour warm water into suitable vessel carefully, then slowly put the medicine, then mix continuously up to uniform solution.

j. Continue the boil out and overflow until overflow is clean and PH less than 9, then shut down the

16

If the boiler has been already used or surely the inside is clean, the above can be done per detail. Besides, caution should be taken to prevent the impurities from the boiler system come into the boiler. In the steam boiler system, the condensate water should be abandoned if the impurities in the condensation system can not be cleaned. And ensure the makeup water quality to prevent impurities.

burner. k. Let the boiler Temp. drop to below 48oc. l. Remove handholes, applying high pressure water to wash the gasket surface. m. Check the inside of PV, boil out again in case there still is dirt existing. n. Replace handholes and safety valves. Heat the water above 83oc to relieve dissolved oxygen.

Drain the steam return water in the first week to clean dirt in main steam pipe and condensate return tube.

o. Prevent corrosion inside the boiler.

17

SECTION 3 CONTROL SYSTEM & BURNER Boiler controls, indicators and switches are mounted in the control panel on the side of the boiler. There are green, yellow and red indicators, green and yellow show the present status, red shows trouble. While the red light usually with the alarm sounds which needs special care. The follows are standard control panel; refer to the detail label on control panel and wiring diagram for applicable special specification with different arrangement. Fig. 3-1 Control Panels

FBC300-650 Steam Boiler Control Panel

18

22

1

5

2

6

7

3

8

10

12

14

11

13

15

4

9

16

17

19

18

20

21

FBC300-650 Heavy Oil/Light Oil Fired Steam Boiler Control Panel Inner View

21

Controls a. Power Indicator (green) Indicates power is on.

shuts off.

b.

i. Boiler Control Switch off/on

Boiler Operation Indicator (green)

Turn this switch to the right, boiler starts up and the green indicator in the control panel lights; the burner programmer starts the pre-ignition purge and detection. As the programmer enters into normal operation, the flame detector will monitor combustion flame all the time, and boiler begins normal operation. If any abnormal is detected by the programmer, the burner would cut out automatically. After burner blower stopped, push the reset button in the programmer, the programmer will auto reset.

Indicates boiler is in normal operation. c. Ignition Indicator (yellow) Indicates ignition solenoid valve is open. d. Main Fuel Valve on (yellow) Indicates burner main fuel solenoid valve with PID regulation open; the burner is in percent regulation status. e. 2nd Low limit water indicator (red) Steam boiler has low water interlock function. When the boiler water level drops below 1st low water probe, burner auto shuts off. Only after the boiler water level returns to the safe working level, burner would auto start again. The 2nd low water relay alarm sounds and indicator ignites if the boiler water level is below 2nd low water limit probe; and the burner continues to shut off. Only after the boiler water level return to normal (about the middle of the water gauge glass) and water relay is manually reset, the burner may auto start again.

j.

Warning: After the 2nd low water alarm sounds, burner starts only after feed water pump works and the water level return to the normal level.

l.

f.

Fire regulator manual/auto

Turn the switch to right, fire will be adjusted automatically according to steam pressure. While in manual position, fire can be controlled by the manual adjust switch in the control panel. k. Manual firing rate regulator Control the burner fire manually while fire regulator manual/auto switch in manual position. When in auto position, manual adjust does not function. Pump manual/off/auto

Switch to manual position while fill the boiler. At this time, the boiler water will not be controlled by water relay. Water level will continuously keep rising for hydrostatic test etc. boiler inspections; Switch to auto position, water relay will automatically shut off pump while boiler water level reaches the normal position.

High water Indicator (red)

It will light while the boiler water exceeds the preset high water level and the alarm will sound. Water feed pump will stop until the water level falls to normal. Alarm will cancel and light will extinguish after back to the normal water level.

m. 2nd low water reset The 2nd water relay works together with 2nd low water probe mounted in boiler. While water is below 2nd low, burner will be shut off and an alarm will sound. The pump feeds water continuously at that time until water is restored to normal, reset 2nd low water relay, then burner will start.

g. Flame failure (red) The lamp will light, alarm will sound and burner will cut off when flame failure. h. High steam pressure (red)

n. Alarm Silencer

When boiler steam pressure exceeds preset level, the indicator lights and alarm sounds, and burner

The alarm will sound while boiler is in trouble to 40

notify personnel to check the problem. alarm can be manually canceled.

whatever ignition or normal operations will lockout the programmer and the fuel electrical solenoid valve is shut at the same time to stop fuel supply.

The

o. Extra high pressure reset

Mounting RM7800 Relay Module

The indicator will light while steam pressure exceeds preset and alarm sounds to notify related personnel, the burner will automatically shut down. Only after steam pressure drops to safe level, reset manually and then the burner continues to work again.

1. Mount the RM7800 vertically on the Q7800 sub base, or mount horizontally with the knife blade terminals pointing downward. When mounted on the Q7800A, the Rm7800 must be in an electrical enclosure. 2. When mounting in an electrical enclosure, provide adequate clearance for servicing, installation and removal of the RM7800, keyboard display module, flame amplifier, flame amplifier signal voltage probes, electrical signal voltage probes, and electrical connections.

p. Emergency stop push button Stop the boiler by pushing the emergency stop button while the boiler is in unpredictable trouble. q. High low water relay & pump relay These relays work together with water probes mounted in the boiler to control boiler water in normal ranges automatically. If water level is too low, burner will be shut off to sound the alarm. Water probes are mounted in two horizontally located probe bases at the top of the boiler. The standard FBC has its 2nd low water probe in left probe base. Boilers with high water alarm will sound to notify personnel to take actions to lower water level while water in boiler exceeds the preset high level. In this time, the burner will continue working. Consult Fulton if you want to shut down burner when water level reaches the high preset level.

Flame Module

Programmer-RM7800

a. Allow an additional two inches below the RM7800 for the flame amplifier mounting. b. Allow an optional three –inch minimum to both sides of the RM7800 for electrical signal voltage probes. 3. Make sure no sub base wiring is projecting beyond the terminal blocks. Tuck in wiring against the back of the sub base so it does not interface with knife blade terminals or bifurcated contacts. Important The RM7800 must be installed with a plug-in motion rather than a hinge action.

Relay

4. Mount the RM7800 by aligning the four L-shaped corner guides and knife blade terminals with the bifurcated contacts on the wiring sub base and securely tighten the two screws without deforming the plastic.

The programmer monitors burner ignition and combustion cooperating with each sensor element per specified procedure; verify excellent flame and detect formed flame. Any abnormal

41

Fig 3-2 RM7800 Module Explode View Flame Establishing Period Model

Initiate

Standby

Post

Purge

Run Maina

Pilot

purge Timing

Interlock

Firing Rate

Circuit

Circuit

Preignition, RM7800L

10S

*

**

4 or 10S

b

10 or 15S

*

15S

Lockout, High and Low Fire

Energy Saving

Code

Prepurge

Bodies

4-wire modulating

*Standby and Run can be an infinite time period. **Purge determined by which ST7800A purge card is selected.

a The MFEP is determined by which terminal is used, configuration jumper selected or jumper wire added. b RM7800L1053：10 seconds or intermittent.

42

Approval

No.

FM/IRI Modulati ng

Fig 3-3 RM7800 Wiring and Program Control

43

b. Working temperature control

Boiler Pressure Control

One temperature set for this purpose:

a. Working Pressure Control

1. When boiler is in normal combustion, water temperature will rise till the set temperature, then the temperature control provides program signal to cut off all the fuel valve and stop burner. (Two situations are listed below)

It controls burner operation and on/off. Shut down burner while pressure reaches preset and start burner while pressure drops to preset difference. c. Limit Pressure Control

2. When boiler temperature falls to one certain data that lower than working temperature in one period of time (the interior setting may be modified), the burner would re-start, then the boiler load is controlled by high/low fire temperature transformer. The boiler is controlled to normal operation as above.

In case working pressure control switch failure, the boiler pressure will exceed preset limit which activates Limit pressure control (the setting exceeds at least 50kpa than that of working pressure switch) to shut down and lockout the burner, and the high pressure indicator will light. d. Modulation Pressure control

When boiler does not shut down as the temperature is at the set working temperature (shows working temperature control is in failure that need repair.), and the water temperature is raised up to high limit, the temperature will provide burning program signal to cut off all the fuel valves and stop burner with alarm, and at that time, the user should check for the working temperature control as interlock explained above.

With automatic burner firing rate percent modulation, reduce the firing rate automatically while boiler steam pressure gradually reaches upper limit of preset; and increase the firing rate automatically while boiler steam pressure gradually reaches lower limit of preset to raise the steam pressure. So the steam pressure is maintained at about preset level by firing rate percent modulation.

c. High limit temperature interlocks control One temperature set for this purpose:

Boiler Temperature Control

When boiler water temperature is raised to set working temperature but not stop boiler yet (shows failed working temperature which need repair). When temperature is raised up to high limit, the high limit temperature will provide signal to burner program to cut off all the fuel valves and stop burner with alarm. The user should check for working pressure control and temperature sensor.(Please consult a qualified technician as quick as possible.)

a. High/Low Fire Temperature Control One temperature set for this purpose: While boiler is started in normal combustion, the control provides signal to burner which calls for high load operation of the boiler. When the temperature is raised close to the setting, the control provides signal to burner in-phase which calls for low load operation of the boiler. That is, to realize flame ratio control against temperature changes.

44

Burner –IC D/Series & S/Series Introduction

Fig 3-4 D series burner

Fig 3-5 S series burner settings for the starter, the rest of the control panel components require little attention except for occasional cleaning.

a. General D series burner is for use with FBC-1000/ FBD-10.5(inc.FBC-1000) and below. S series burner is for use with FBC-1300 /FBD-10.5 and above.

c. Combustion Air Handling System D/series

The burner is assembled, wired and tested output.

The combustion air handling system consists of three major components:

The operator must be familiar with the individual functioning of all controls to understand the operations and procedures described in the manual. Identify and locate each item in the illustrations as they are described in the following sections. b.

Description

The industrial Combustion D/S series oil burners are of the low pressure, air atomizing (nozzle) type. Gas burners are of the periopheral mix type. All burners feature ignition by spark-ignited gas pilot flame. With either fuel, the burner operates with full modulation. A switch permits changeover from automatic fully modulated firing to manually set firing at any desired rate between minimum and maximum. Additional safeguards assure that the burner always returns to minimum firing position for ignition.

Fig 3-6 D Series Burner 1. Damper Assembly A rotary damper regulates the combustion air volume and is positioned by a modulating motor. The damper is normally ALMOST CLOSED in the low fire position and opens as the burner drives towards a high position.

The burner is designed for automatic, unattended operation except for periodic inspection and maintenance. After selecting the proper overload 45

cycle or 60 cycle power and for firing against either moderate or high furnace pressure. For higher altitudes and higher furnace pressure, motor and impeller combinations are determined at the factory.

2. Motor Driven Impeller The diameter of the impeller determines available air pressure and the width determines air capacity in cubic feet per minute. Alternate motor-impeller combinations are available for 50 cycle or 60 cycle power and for firing against either moderate or high furnace pressure. At attitude up to 2000ft. above sea level, model S impellers are recommended for up to 1.5” W.C. Model “p” impellers are recommended for furnace pressure from 1.5”-4” W.C. furnace pressure. For higher altitudes and higher furnace pressures, motor and impeller combinations are determined at the factory.

d. Firing Rate Controls Regardless of the fuel used, burner input is fully modulated between low fire and high fire on boiler demand. Firing rate is controlled by the potentiometer-regulated modulating motor. Combustion air control damper, oil metering valve and/or gas volume butterfly valves are through variable rate and lever linkages. The modulating motor rotates 90 degrees from low to high position.

3. Stator cone The stator cone in the air housing transforms the rotating air velocity pressure to static pressure prior to air entry into the blast tube.

Flow rate through each component is adjusted by positioning the control rods on the levers and the angular position of levers on shafts. Lever on the modulating motor shafts actuate the high fire position proving switch.

S series 1. Damper Assembly

e. Firing Head

A multi blade system regulates the combustion air volume and is positioned by a modulating motor. The dampers are normally ALMOST CLOSED in the high fire position. LOW

Access to the firing head is provided by swinging open the impeller housing. First, disconnect the damper linkage, release the housing latch and swing the housing to open position. An internal gas pilot is standard on all burners. Pilot gas pressure is adjusted at the pilot pressure regulator.

2. Motor Driven Impeller The diameter of the impeller determines air capacity in cubic feet per minute. Alternate motor-impeller combinations are available for 50

FIG. 3-7 D Series Firing Head

46

Fig. 3-8 S Series Firing Head f.

mixes with fuel oil. Air/oil passes through grooves and out of the nozzle orifice in a cone of atomized oil. Proper velocity and angle of the fine spray ensures good mixing with the combustion air, providing quiet starts and excellent combustion

Oil System Air Atomizing

The burner compressed air for atomization. Atomizing air is independent of combustion air. The system is supplied with a separate compressor module for mounting near the burner. Depending on burner size and fuel, one system for model DL, DM, DLG, DMG No.2 through 5 oil with air atomization (model D42 to 145) uses an integral air compressor/oil metering unit mounted on the burner and is driven by a separate motor.

efficiency. Nozzle Line Electric Heater (D Series) Provides heat for No.4, 5 and 6 fuel oil for cold starts and is located between the metering pump and 3-way valve. This heater should not be used as a continuous run line heater. Heater has an adjustable thermostat and a cold oil lockout switch which prevents burner from starting until proper atomizing temperature is attained.

3-way Solenoid Valve Metered oil enters the common port of the 3-way solenoid valve. During shutdown, pre and post purge the valve is de-energized (N.C. port closed) and all metered fuel oil return to the storage tank. When the valve is energized, metered oil is directed to the nozzle through the N.C. port.

Oil Strainer Prevent foreign matter from entering the burner oil system.

Nozzle Assembly

Atomizing Air Proving Switch

The nozzle assembly consists of four main parts: body, compression spring, swirler, and tip. The swirler is held against the nozzle tip by the compression spring.

Pressure actuated switch contacts close when sufficient atomizing air pressure is present. The oil valve will not open unless switch contacts are closed.

The nozzle body has inlet ports for air and oil lines. Metered fuel oil enters the nozzle body and flows the core of the swirler to the side parts where it meets with the atomizing air.

Separate Compressor Module All Models (used with FBC series) have a burner mounted oil metering unit and a separate compressor module. The system functions as follows:

Atomizing air enters and passes through the nozzle body to grooves in the swirler, where it

Air Compressor Module

47

Air is supplied by a positive displacement rotary vane compressor. This provides a constant volume of atomizing air regardless of pressure. The compressor module includes air-oil reservoir tank, air filter and the lube oil cooling oil. Air enters the compressor through the filter. The air flows from the compressed air. T he tank air pressure forces lubricating oil from the tank to the compressor to lubricate bearings and vanes. A sight glass indicates the level of lubricating oil in the air/oil reservoir. Lubricating oil must be visible in the gauge glass at all times. Air compression heat is absorbed in part by the flow of lube oil, creating a hot oil mist. The air/oil mist is cooled by a coil assembly. Lube oil is also cooled before entering the compressor.

D series Integral Unit Fuel oil under nominal pressure in the circulating loop, flows to the adjustable positive displacement, (volumetric) metering unit. Oil metering is accomplished by changing the piston stroke by means of an eccentric shaft and pin assembly. Fig. 3-10 Integral Oil-air System and Tank

Oil Metering S series The oil metering unit is a MAXON Synchro flow control valve. The multiple screw cam assembly provides mechanical adjusting capabilities to the fuel ratio at each valve position throughout entire capacity range.

The pistons reciprocate in a rotor assembly, turning in a hardened steel sleeve having oil inlet and discharge slots. During each revolution the pistons go through the following cycle:

Fig 3-9 Oil Piping Assembly

1 inlet cycle: The piston is at the bottom dead center position. At this position, the cavity between the top of the piston and the outside diameter of the to fills with oil. 2 Discharge Cycle: The piston is at the top of dead center position. At this position, the oil is forced out of the discharge port to the nozzle. The piston stroke length is determined by the position of the eccentric shaft and plate. The piston adjustment plate is positioned by an adjustable eccentric shaft. The eccentric shaft is positioned by the modulator through adjustable linkage. Counterclockwise rotation of the eccentric shaft increases the piston stroke (more oil delivered to nozzle); clockwise rotation decreases the amount of oil delivered.

48

For the description of typical fuel oil piping installations, see section 2. Air enters a rotary vane compressor through an air cleaner where it is compressed to atomizing pressure. Air flows from the compressor to an air/oil tank which serves the multiple purposes of dampening air pulsation, lube oil mist recovery, lube oil and atomizing air storage. The compressor rotor is cooled and lubricated continuously by oil under pressure from the air/oil tank. Oil vapor is extracted by a mist eliminator in the upper section of the tank. Atomizing air from the upper tank section is delivered to the nozzle at a constant volume. Air pressure increases as the burner firing rate increases. Atomizing pressure may be adjusted by the needle valve located on the air-oil pump. The valve allows air to be bled from the tank to the compressor. Delivery rate of the fuel oil metering pump is controlled by the modulating motor through adjustable linkage.

When the eccentric shaft is stationary, at any position, the stroke of the pistons remains constant delivering a constant volume of oil regardless of viscosity. Separate Unit The oil metering unit is cored with channels through the housing. Fuel oil circulates through these channels keeping the metering unit warm to prevent heavy oils from congealing when the burner is idle.

Gas System Fig. 3-11 Fuel Oil metering System (Used with Separate Compressor) Operation Fuel is delivered to the positive displacement metering pump at 10 to 15 psi. Metered oil is delivered to the common port of a 3-way solenoid valve for transfer to the burner nozzle through the normally open port. During pre and post purge, metered oil is delivered to the nozzle. Heavy oil burners have a supplementary nozzle line heater between the metering pump and the 3-way valve.

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SECTION 4 Boiler/Burner Operation Starting Boiler

Fig 4-2 Shut interlock fuel valve for dual fuel burner

Stop! Make sure you have read any followed information for safe and correct boiler operation. If need Permitting before start up, please consult local government. Ensure boiler location meet the requirement of boiler installation with reference to local rules. Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down.

Fig 4-3 Open steam gauge isolation valve Preparation a. Make sure that all the followed valves are closed: Boiler main blow down valve, water gauge blow off valve.

Fig 4-4 Open all the valve s on feed water line

Fig 4-1 Close main blowdown valve b. Make sure all the followed valves are opened: Main steam valve/hot water valve/return water valve, steam/hot water gauge isolation valve, all of the valves on water feed line, water gauge isolation valve, all of the valves on oil supply and return oil line, gas supply valve.

Fig 4-5 Open Water assembly isolation valve c. Ensure burner switch to off

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Start Burner Fig 4-6 Burner switch to OFF d. Switch the pump manual/off/auto to off position.

a. Ensure all of the fuel valves have been opened. b. Ensure no lockout on programmer safeguard and trouble removed. c. Ensure rotation of burner and oil pump. d. Turn on boiler control selector, and boiler is started. The switch is in manual position while boiler starts from cold, and should be in low fire; after steam is discharged from the safety valve that at the top of boiler, close it. The boiler high/low fire switch is at auto position after pressure is raised.

Fig 4-7 Pump switch to OFF

Note

e. Turn on the power switch in control panel.

The operator should check and pay attention to the following while boiler is in operation: a. Water level in water gauge should be slightly waved around the normal, not but wave seriously or water level slur. b. Steam pressure and gas pressure is steadied at normal. c. The sound of blower and water pump rotation should be steady without too loud voice etc. abnormal. d. Slowly open valves esp. high pressure in boiler. f. It is normal that the burner automatically operate at low fire, high fire, shut down or restart etc to follow the change of steam pressure or hot water temperature by responding the signal from pressure/temperature regulator.

Fig 4-8 Open power switch in control panel f. Switch the pump manual/off/auto to auto position to start pump until boiler water reaches pump off position. For hot water boiler, please switch on feed pump power till boiler and system filled with water, then close boiler exhaust valve and maintain normal pressure at circulating pump and boiler net output.

g. Shut down while suddenly flame out , extra pressure/temperature, and abnormal water level etc. during operation; and check for boiler pressure, water level, fuel supply and gas pressure, air pressure etc.. The professional personnel will undertake troubleshooting if do not operate without any abnormal.

g. Switch light oil/heavy oil to heavy oil position for boiler with heavy oil to start heating system for applicable temperature.

h. Air is vented in the boiler room esp. take care fuel leakage.

h. Turn on circulating pump of oil boiler, with circulating pressure at preset.

j. Heating temperature and circulating pressure for heavy oil line.

j. Gas pressure should be at preset for gas boiler. 51

Shut Down Boiler

Boiler Pressure Control

Short term

a. The pressure of working pressure controller is set as used steam pressure. For example, the used steam pressure is 8bar, then working pressure controller set is 8bar and the limit pressure set is 9bar. Two knobs located on the top of ratio adjust pressure controller (big and little, see fig.) The big one is used for working pressure set, clockwise rotation increase the pressure and counterwise will decrease.

Turn boiler on/off in burner or boiler control panel to OFF. The burner will stop firing, post-purge and then stop. Medium Term (Days) a. Turn boiler on/off in burner or boiler control panel to OFF. The burner will stop firing, post-purge and then stop.

b. The little knob is used to adjust pressure difference between start and shut down. Clockwise rotation will increase the pressure difference and counterwise decrease. For example, the difference set is 0.5bar, limit pressure controller and working pressure sets are 9bar, 8bar, and the boiler operation will change with steam pressure. While steam pressure reaches 8bar, boiler shut down, and while pressure is reduced to 7.5bar, boiler will start automatically. The limit pressure controller is the protection of working pressure controller. While working pressure controller is in trouble or damaged, it performs the second protection to shut down burner and alarm.

b. Shut main steam valve. c. Shut the water feed valve. d. Shut fuel valve. e. Turn the power switch on the boiler control panel to off. f. Shut heavy oil heat source, stop circulating pump. It is recommended to purge the heavy oil pipeline with light oil in case of shut down boiler more than one week to avoid block the pipeline next time. Long Term (Weeks) To store the boiler in a corrosion–free situation there are three practical solutions as follows: a. Wet storage is usually used for shot term shut down, or situations that dry storage can not be carried, and ensure ambient environment not too low. It is recommended blow down first to fully clean PV inside, and fill the boiler with treated water (Maintain PH etc. value). If the water were not oxygen removed, operate boiler for a while, or use some chemical medicine, such as sodium sulfite aqua (properly added this medicine as well during normal operation) to reduce the corrosion in boiler to the least. Water pressure in boiler should be greater than atmospheric pressure; use nitrogen for pressure increase. Deposited carbon on insulations should be cleaned.

Fig 4-9 Percent Modulator

b. Dry way is usually used for boiler with long term shut down, or environment temperature reduced to zero during shut down. Boiler must be dry completely for dry way to avoid corrosion from humidity. PV Inside and outside surface should be cleaned at all, remove all of the deposit and put enough dry medicine (at least 2 pounds per 3 cubic feet). Heating surface that contact with high

Fig 4-10 W.P modulator/Limit pressure Modulator 52

Check one time every 5 years for 24 hours continuous operated boilers with the weld of shell to front and rear tubesheet, and the longitudinal seams is one time every 10 years.

temperature flue gas may be covered by corrosion-free, grease etc. materials. Remove deposited carbon on insulations and close handholes, manhole, water feed and steam valves. (Note: All should be taken out while start up.)

Warning: Do not operate safety valve without any proper protection because of high temperature in the valve and its accessory. While manually check it, the open pressure must more than 70% of the rated and pull handle more than 5 seconds.

Note 1. For one FBC firetube steam boiler, furnace, firetube and shell are welded to front and rear tubesheet to construct a PV unit. Each part of boiler operates at different temperature, and the rate to working temperature varies due to different water and steam temperature in the boiler.

Burner Operation 1. Boiler Check the boiler water level. Be sure all boiler valves are installed correctly and positioned properly. Set the high limit control slightly above the desired temperature. Set modulating controls at the desired temperature or pressure.

2. As boiler start from cold, the different expansion proportion will transfer the mechanical pressure to the weld, proper design for boiler ensures that all the pressures can be absorbed. If frequently start from cold, the life of boiler and interval between two inspections would be shorten. It is recommended to possibly slowly heating to start up the boiler and maintain pressure as possible as you can.

2. Burner Check the electrical power supply to the burner in accordance with the nameplate voltage on all motors and the control circuit. Check the direction or rotation of the motors. Open the housing to check the electrode setting. Check the gas pilot pressure at the pilot regulator. Normal setting: 3” to 6” W.C.(D series ); 18”-20” W.C. (S series).

3. The best operation: while start from cold, gradually raise the temperature and pressure. The detail is: first heat a few minutes in low fire, then let heat freely spread in the boiler (continue 20-30 minutes); and then blow down boiler suitably to lower top water for heating bottom water. At next circulation, increase heat time and decrease spread time.

Check control linkage for proper movement of the air volume damper and fuel metering components. This can be done by loosening the linkage at the actuator level and manipulating by hand.

4. During actual operation, may be the above is not realism. However, if the boiler had been operated yesterday, the heat collected in the boiler will maintain the temperature at a certain level, so directly start the boiler at that time and reach working temperature/pressure.

Check the shutter and adjust low fire setting. 3. Firing Preparations for Oil Burners Prior to initial firing, oil flow pressure and temperature should be verified. Inspect the compressor lube oil sump level. Add oil to bring the oil level to the midpoint or slightly higher in the reservoir sight glass.

5. At the last operation period, shut the steam valve to maintain certain pressure which ensure temperature in boiler do not change greatly during night.

Make certain that the drive belts or couplings are aligned and properly adjusted.

Joint Inspection

To verify air flow and pressure, momentarily flip the switch “ON” and immediately turn “OFF”. The programmer will continue through its cycle, however, without ignition or energizing the fuel

The time interval between two inspections of weld joint is determined by the start times (start from cold to W.P. is one time) after last check.

53

pressure valve. This should be set between 10-15psi (DL & DM models) or 12-20psi (DE models) at the burner inlet after the temperature stabilizes.

valves. Observe the air pressure gauge. With compressor running and no oil flow, the pressure should be approximately 10psi. If the burner is a dual fuel model, make certain that the main gas shut off cock is closed and the fuel selector switch set to “OIL”.

Heavy oil flow and burning characteristics are dependent on oil viscosity, which in turn requires temperature regulation. A loop heater in the supply line between the circulating pump and the burner heats the oil. The loop heater should be adjusted to give the designed operating temperature. Where the burning characteristics of fuel are unknown,

Oil Flow D Series Light oil: open all valves in the oil suction and return line. The burner oil metering units are not capable of creating suction. Fuel oil must be supplied to the metering unit at a nominal 10 to 15psi pressure by a circulating supply pump.

No.4 No. 5L No.5H No.6

Heavy oil: Refer to piping diagrams for burners using heavy oil. Note the by-pass valve between the supplies and return lines. At initial system start-up or after prolonged shutdown, start the system as follows:

80OF -125OF 115 OF -160oF 145 OF -180oF 180 OF -220oF

e. Oil-Air Tank (Lube Oil) Check the lube oil level in the air-oil tank. Inspect oil level regularly. Loss of oil will damage the compressor. Fill the tank with non detergent SAE30 oil to a level midway up the sight glass. Do not overfill the tank.

a. A vacuum (or compound pressure-vacuum) gauge should be installed in the oil suction line, and its reading noted. This gauge indicates the tightness of the suction system.

For normal environment use SAE30 oil. For a 32 degree F. and below environment use SAE10 oil. Change oil every 2000 hours of operation.

b. Open valve No. 1 in the bypass line and close valve No.2 in the supply line to the metering pump.

S series Open all valves in the oil suction and return line. The burner oil metering units are not capable of creating suction. Fuel oil must be supplied to the metering unit at a nominal 50 to 70psi pressure by a circulating supply pump.

c. Turn on the pre-heater and the circulating pump. Oil will circulate from the tank through the circulating pump and pre-heater, returning to the tank through the bypass and return lines. Observe the oil supply pressure gauge for indication that oil flows is established. If no pressure shows after a few moments, and the vacuum gauge shows little or no suction, stop the circulating pump and re-prime. Heavy oil in the storage tank (I.E. hot well) must be warm enough to permit flow.

4. Firing Preparations for Gas Burners A representative of the gas utility should turn on the gas. Determine by a test gauge upsteam of the burner regulator that sufficient pressure exists at the entrance to the gas train. The gas pressure regulator must be adjusted to the pressure required and the pressure setting recorded.

d. As the system becomes warm, the pressure required for circulation will gradually drop. When the return is warm, open No.2 valve and throttle the flow trough the back pressure valve to the tank via the return line. The pressure in this loop around the burner becomes warm, gradually close valve No.1 in the bypass line. All supply oil will then flow through the burner loop.

On combination fuel models, set the selector switch to gas. On initial start-up it is recommended that the main gas shut-off cock remain closed until the programmer has cycled through pre-purge and pilot sequences to deter. Check for leaks and determine there is adequate

The system pressure is regulated by the back 54

Close the main and pilot gas cocks. Make sure the ON-OFF switch is in the OFF position and the fuel selector switch on GAS. Actuate the manual reset button of the flame safeguard control to close the safety switch contacts. Set the MANUAL-AUTO switch in the MANUAL position. Set the manual potentiometer in low fire position. Open the gas pilot cock.

gas pressure available at the burner for operating at full capacity. Check with the local utility if necessary. Check gas pressure at the pilot and the main burner. Close the manual gas valve. 5. Electrical Interference Test Prior to putting the burner into service, conduct the following test to ascertain that the ignition spark will not cause the flame relay to pull in.

Set the ON-OFF switch to ON. The burner will start and pre-purge. After pre-purge, the ignition transformer and the gas pilot solenoid are energized. Before proceeding, conduct electrical interference and pilot turndown tests if not previously done.

a. Gas Fired Close the pilot and the main line manual gas valves. Start the burner and at time of pilot trial with just the electrical ignition system energized, the flame relay should not pull in (i.e. be energized)

On initial start-up it is recommended that the main gas shutoff cock remain closed until the programmer has cycled through prepurge and pilot sequence. Then determine that main gas valve opens. When this is confirmed, turn the burner switch OFF and let programmer finish its cycle. Check to see that gas valve has closed tightly. If ignition does not occur, turn the burner switch off and allow programmer to recycle for a new ignition trial.

Upon completion of successful test, proceed with start up procedures. b.Oil Fired Disconnect the electrical power to the burner. Disconnect the electric oil safety shut-off valve. Reconnect electric power to the burner. Close the pilot line manual gas valve, if used. Start burner and at the time of pilot trial, with just the supply. Reconnect oil safety shut-off valve and turn on manual pilot gas valve. Reconnect power supply and proceed with start-up procedures.

Turn burner on and after pilot ignition when the flame relay pulls in, the slow opening, motorized, main gas valve is energized. Slowly open the downstream manual shutoff gas cock. Main flame should ignite at this time. The gas valve and air damper continue advancing until high fire is reached.

6. Gas Pilot Flame Adjustment The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator. Normal setting is 18” to 20”(S series); 3” to 6” (D series) W.C. when the pilot is burning. The flame must be sufficient to be proven by the flame detector and ignite the main flame.

Do not repeat unsuccessful light off attempts without rechecking burner and pilot adjustment. Vent fuel vapors from the combustion chamber after each unsuccessful butterfly valve and air linkage. When low fire is adjusted, shut down burner. Restart several times to be sure the low fire setting is suitable. Readjust if necessary. Never start the burner with fuel vapor in the furnace. In case of emergency, open main power switches and close all fuel valves. After combustion adjustments are satisfactorily set, allow the heating vessel to slowly reach normal operating pressure or temperature.

Although it is possible to visibly adjust the size of the pilot flame, obtain a proper DC volt or microamp reading of the flame signal. The flame safeguard amplifier has a meter jack for this purpose. At initial start-up and during planned maintenance, test the pilot flame signal, pilot turndown, and safety switch lockout. 7. Start-up Sequence

Turn the potentiometer switch to the high fire position. Check high fire at this point using combustion instrument.

Gas Burners 55

Do not disturb established low fire adjustment. Allow the burner to return to low fire position before adjusting high or intermediate settings.

a. The operating and high limit control (temperature or pressure) are below their cutoff setting.

High fire combustion analysis typically is 9 to 10.5 percent CO2.

b. All power supply switches are closed. c. Power is present at the control panel.

Oil Burners

Refer to the manufacturers’ literature on programming controls and burner wiring diagrams for detailed information.

The fuel selector switch should be set to OIL. On initial start-up of a combination burner, it is recommended that oil firing be adjusted before gas firing. Gas low firing rate is set to match oil low fire rate.

a) Begin staring sequence, with burner switch off, and with all manual valves closed. Switch main power on. (POWER ON ) light.

Be sure the ON-OFF switch is in the OFF position and the fuel selector switch is on OIL. Actuate the manual reset button of the flame safeguard control to close the safety switch contacts. Be sure the MANUAL-AUTO switch is in MANUAL position. Set manual modulating control potentiometer in “LO” fire position. Open the pilot gas valve.

b)

When firing oil, open the manual oil valves.

c) When firing on gas, open the main manual gas valve. d) When firing on gas, manually reset the high and low gas pressure switches. e) Place the gas/oil selector switch in position for desired fuel. With all limit and operating controls calling for heat, the burner will follow the Flame Safeguard Sequence below.

Set the ON-OFF switch to ON, The burner will start and pre-purge. After pre-purge, the ignition transformer and the gas pilot are energized. Before proceeding conduct electrical interference and pilot turndown tests if not previously done.

f) When the burner motor starts, open the gas cock.

Observe the primary atomizing air pressure gauge on the air/oil tank. The gauge reading should be approximately 10psi during pre-purge.

g) If firing on gas, when the main fuel lamp lights indicating pilot flame proven open the manual leak test valve.

When the pilot flame is proven, the programmer will proceed to the main flame position. Allow the burner to operation in low fire, to warm the boiler before moving to high fire.

Time (s) 0

Typically, for No.2 oil, CO2 is 8 to 11 percent at low fire. Turn the manual potentiometer switch to the high fire position. Check high fire combustion at this point. Do not disturb previously established low fire adjustment. Allow the burner to return to low fire position before adjusting high or intermediate settings. The primary atomizing air pressure will increase. The programming control sequences the operation of all controls and components through the starting, ignition, firing, and shutdown cycle. The burner and control system are in staring condition when:

56

External Operation Provided the fuel valve is proven closed the burner motor and flame safeguard timer will start.

7

Air flow must be proven before ignition, or the flame safeguard will lockout. If the interlock circuit opens during a firing period, the burner will shut-off and the flame safeguard will lockout.

60

Firing on gas and providing the air flow and low fire have been proven, the air flow and low wire have been proven, the pilot ignition transformer and ignition lamp are energized and the gas pilot valve opens to ignite the pilot.

70

80

1) Condition must be corrected and the respective gas pressure switch manually reset before the burner will fire again on gas.

Firing on oil, providing air flow and pilot has been proven, the main fuel lamp lights. When on gas or oil, the main valve opens to ignite the burner at low fire.

11. Normal Operation Normal operation must be with the MANUAL-AUTO switch selector at AUTO.

The pilot ignition transformer is de-energized, and the main safety shut-off pilot valve closes, scanner proves main flame only. If the low/auto. switch is in the auto position, the following will occur:

In automatic operation, the operating cycle always proceeds sequentially through pre-purge, pilot ignition, main flame ignition, run and post –purge. The length of purge and ignition trial varies according to the type of programmer used.

On gas, the butterfly valve and the burner air louver moves to low fire position. On oil, the metering pump and the burner air louver moves to low fire positions.

During the run cycle, burner input is regulated to the load demand by the modulating pressure or temperature control on the boiler. The burner will continue to modulate until the operating pressure or temperature is reached.

8. Automatic Shutdown

Programmer control operation should be tested when the burner is initially placed into service, when a control is replaced, and at scheduled intervals in the maintenance program.

Limit or operating controls open: 100

Fuel valves close. Main fuel lamp goes off. Flame safeguard timer starts.

115

Flame safeguard timer and burner motor stop. Burner is ready for start up on the next call for heat.

12. Shut Down When the operating limit control setting is reached or the burner switch is turned OFF, the following sequence occurs:

9. Manual Shutdown

The fuel valves de-energized and flame will extinguish. The blower motor continues running during post-purge.

a. Turn gas/oil selector switch off. Burner shuts down in Automatic Shutdown as above. b. When burner motor stops, close all manual valves.

At the end of the post-purge, the blower motor is de-energized. The programmer returns to its staring position and stops. Unit is ready to restart.

10. Safety Shutdown a. If any time during the operating cycle a flame failure occurs, the burner shuts down as in Automatic Shut down, with an additional post-purge, and the flame failure lamp is energized.

Abnormal shutdown might result from motor overload, flame outage, low water, current or fuel supply interruption, combustion or atomizing air pressure below minimum level, tripped circuit breakers, blown fuses, or other interlock devices. Check for cause and correct before restarting burner.

1) The lockout switch on the flame safeguard control must be manually reset after a waiting period of two minutes, before the burner will fire again.

Safety shutdown caused by ignition or flame failure will actuate a red indicator light and energize an audible alarm (if so equipped). If the programmer has a non-recycling interlock circuit, any interruption in this circuit during the pre-purge or firing cycle will cause a safety shutdown. This type

b. If a low water condition occurs, the burner shuts down as in Automatic Shutdown. c. If a high or low gas pressure condition occurs while firing on gas, the burner shuts down as in Automatic Shutdown. 57

of shutdown requires manual reset of the programming control and must be corrected before

operation can be resumed.

58

SECTION 5 MAINTENANCE the pump starts after water level drops.

To ensure the continuing efficiency of the boiler, regularly carry out regular routine maintenance procedure as detailed below:

3. Shut the valve if the main blow down is open to ensure pump continuous feed water to normal water level and shut down automatically.

Caution

The first low water and second low water:

If any fault is found during these procedures, shut down the boiler immediately and consult Fulton.

1. Turn the Pump MANUAL/OFF/AUTO switch in control panel to OFF position.

Note

2. Reduce water level in boiler with blow down or vaporizing.

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 feed is effective.

3. Check water in water gauge, the burner shut down while water level is dropped to low water position; and the low water alarm sounds while water keeps drop, with the second indicator lights and burner continues to shut down.

The lower handhole doors should be removed after three months and the interior of the boiler thoroughly examined. If the scale or sludge build-up is observed, a water treatment specialist should be consulted.

4. If the main blow down valve is opened, shut valve, turn the Pump MANUAL/OFF /AUTO switch to AUTO position to ensure pump start. Then boiler water is restored to normal; the second low water indicator will extinguish and alarm will cancel, and burner returns to operation.

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.

Check Pressure switch: 1) Start boiler

Regular Check

2) Shut main steam valve

Caution: if your boiler can not pass the following test, shutdown boiler and consult Fulton.

3) Turn the W.P. switch to the greatest. 4) Adjust the high limit pressure switch to the value 0.5bar lower than safety valve preset.

After fired the burner, carry out the following tests:

5) Let steam rise up to actuate high limit pressure control. Check the indication on pressure gauge, it should show 0.5 bar lower than safety valve setting. If the indication is wrong, repeat the above.

Flame detector test Remove the detector from the burner joint, and shield the window, then the burner programmer should be immediately lockout (gas boiler 2-3s, oil boiler 5s.), which needs manual reset to restart. Clean the scanner before reinstall.

6) Open main steam valve to reduce steam pressure. 7) Set the W.P. switch at desired pressure, set firing pressure switch to 0.5-1.0 bar lower than W.P. setting.

Water pump Check 1. Reduce water level in boiler through blow down or vaporizing. 2.

8) Shut main steam valve.

Check water level in water gauge, and see if 59

9) Change the above switch set to raise steam pressure actuating high/low pressure switch to change the burner to low fire condition, then shut down burner by the W.P. switch.

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.

Warning: Any change of the burner setting should be completed by professional personnel.

Hot Water Temperature It is recommended that the hot water temperature should be not less than 77℃. The steam exhausted with flue gas would condensate and then cause corrosion to chimney and boiler when the temperature of hot water applied by the system less than 77℃, which is close to the dew point. Condensate can seriously affect the boiler intermittent operation. So, control boiler hot water above 77℃.

High water level probe: (if installed) 1.

Check if the water feed valve is fully opened.

2. Turn the Pump Manual/Off/Auto switch to Manual position. 3. Start water pump, the boiler is filled and water level will be raised. 4. While water rises to high water position, high water indicator will light, and the alarm will sound, but burner will still keep working; switch the Pump Manual/Off/Auto switch to AUTO position immediately, then pump will stop.

Note: It is recommended that the lowest water temperature of the boiler should be above 77℃, if the temperature lower than 77℃ is needed in the system, and then decrease the water temperature

5. Reduce water level in boiler by way of blow down or vaporizing.

Quick water exchange

6. Boiler water level is gradually recovered to normal position, and the high water indicator will extinguish and alarm will cancel.

Do not feed too much water in short time which cause stress raised in boiler pressure vessel. Note: Circulation pump should interlock with burner, that is, when the circulation pump does not work, the burner accompanied to avoid damage to equipment.

Evaporation Test to verify low water relay 1. With the burner running, switch off the boiler feed pump and allow the water level in the boiler drops by evaporation.

Continuous water flow

2. When the water level reaches low water position, the 1st low water relay will function and the burner will stop.

Maintain water flow through boiler by system pipeline at any circumstance. Check for three-tee valve and system control to ensure boiler not to be bypassed. Continuous cycle water flow through boiler would keep system temperature more steady. After the blow down and ignition, boiler operator should check the water flow prior to re-ignition.

3. Allow the evaporation process to continue until the 2nd low water alarm sounds and the 2nd low water indicator illuminates. 4. Switch the feed pump to the pump AUTO position. 5. The water level will be restored to normal working level, the low water indicator lamp will extinguish and the alarm will cancel.

Daily Maintenance Ensure turn off power supply and fuel supply after shut down.

Note: Because the burner shuts down during this test, it is possible that the steam load will rapidly decrease the pressure in the boiler

Ensure boiler house is vented at any time. Always check the air inlet of burner to ensure air is vented 60

Test boiler low water alarm and normal shut down by way of low water probe test.

without any block. The regular should be carried out blow down to keep boiler and water gauge pipework clean and free from sludge and scale build-up.

Test boiler high water alarm by way of high water probe test. Carry out regular routine check for the burner as the recommended code from manufacturer.

Boiler blow down 1. Fully open the main blow down valve for a minimum of 10 seconds after boiler pressure is decreased to 0.34MPa. 2.

Test boiler flame control by way of flame scanner test. Turn off burner power, remove UV scanner and shield. Connect the power to see if the burner would be lockout at the ignition process.

Shut main blow down valve.

Note As well as removing sludge from a boiler, a second and equally important function is to maintain the water quality within the required limits, with caution to the dissolved solids in water. The amount of blow down, and hence time required, is dependent on the amount of dissolved solids in the raw water supply, the percentage condensate return, water treatment chemicals added and the number of hours a day operation etc.. In order to establish the required blow down rate, consult your water treatment specialist who will recommend a water treatment program in terms of appropriate chemicals and the required blow down rate which takes these factors into account.

Shut off power supply, replace the UV scanner. Connect power and replace.

Semi-Annually Caution The boiler must be completely cold before carrying out any of the following procedures. 1. Ensure that the following valves are shut: The main steam valve The feed water isolation valve Fuel valve (oil/gas) 2. Ensure that the power supply to the boiler is switched off. 3. Empty the boiler. It will be necessary to allow air into the boiler before it will drain via the main blow down valve.

Water Gauge Blow Down 1. Open water gauge blow down valve while the pressure in boiler is lower than 0.07MPa, and then in turn shut the bottom isolation valve and top isolation valve.

4. Remove the handhole and manhole doors and thoroughly inspect the internal surfaces of the boiler, paying particular attention to the junction of the tubes with the front tube plate and the tubes for signs of pitting. Any deposits should be removed and your water treatment specialist consulted. Ensure there are no accumulated deposits of sludge in the bottom of the boiler.

2. After blow down, ensure all the isolation valves are opened and all the blow down valves are closed.

Weekly Check for the handholes and man hole for signs of leakage. This is particularly important when the boiler is started from new or when gaskets have been replaced. Corrective action taken as soon as a leak occurs can prevent costly repairs later.

5.

Remove the front smoke door.

6.

Remove the rear smoke door.

Check for signs of leaks on all valves and fittings and take the appropriate action.

8. Using a wiring brush, clean the internal surfaces of the furnace and the face of the front

7. Brush through the tubes to remove any deposits from the products of combustion.

61

then the housing can be turned to right, pay attention the wiring in burner. The ignition assembly is at the right of the burner. Break the ignition electrode terminal to remove the air tube and carefully take the assembly out from the burner head.

tube plate. Pay attention to the tube ligaments. 9. Inspect the tube ends for any signs of splitting or burning. These are symptoms of gas returning 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.

Oil Nozzle Assembly

10. Clean out the rear smoke box.

Remove the air damper linkage, turn the firmed clip upward (for DL175 below is manual rotated screw), then the housing can be turned to right, pay attention the wiring in burner. The nozzle assembly is in the center of the burner. Remove the air tube and oil supply tube, remove the fixed screw and carefully take the assembly out from the burner head.

11. Inspect the door seal for signs of wear and replace if necessary. The first indication of a worm door seal would be evident by signs of black around the external periphery of the door. 12. Examine the internal surface of the door refractory lining for defects. Small repairs may be carried out by cutting out the defective area and replacing with new fiber.

Airing Flame Stabilizer

13. Examine the end of the burner blast tube. Clean off any deposits, paying particular attention to the internal lip where deposits can cause irregular flame patterns.

Use wire brush to clean after open the burner. Ignition Electrode Check and clean, check for crack in pottery and replace for crack.

14. Inspect the rear smoke box door seals for deterioration and replace if necessary.

Flame Scanner

15. Close the hinged front access door by reversing the opening procedure.

Use clean cloth and do not contact the glass with finger or others. Pay attention to align the glass face to flame.

16. Re-connect the gas/oil connections. 17. Drain and flush the feed water tank, clean any fitters and the strainer in the feed line.

Oil Strainer Remove rear oil pump plate to get the strainer out and use clean diesel oil or other similar solvent. Reinstall it and recover the plate.

18. Drain and flush out the blow down separator. 19. Clean oil line, oil strainer and oil tank (oil boiler).

Replace at least one time every year for once strainer. The detail frequency is up to the cleanness of oil and installation. If not, always wash or replace the core.

20. Carry out routine maintenance to the burner as following. Note Remember shut off power before any action is taken on the burner.

Note: Exhaust air in system after completion of above.

There is usually no need to clean because of self made by centrifugal designation.

First wash with detergent for nozzle strainer after the nozzle is separated, then wipe residual dirt with clean cloth, do not use any metallic of wood material.

Gas Burner Ignition Assembly

Motor

Remove the air damper linkage, turn the fixed clip upward (for DL175 below is manual rotated screw),

No need for maintenance. If the bearing is wrong, replace. If the coil is bad, replace.

Burner Impeller

62

Elastomeric Vulcanizates, which form the basis of TOPOG-E gaskets, undergo degradation from many sources including heat, oxygen, stress, and overdosing from certain types of water treatment. This takes the form of material oxidation, the form of material oxidation, hardening/embrittlement and cracking which may take to minimize the effects of such attacks.

Control Panel In general, no need. Do not open the cover unless special situation. If necessary, ask for professional personnel or tighten the screw. Note: The purpose of regular routine check is to ensure no scale build up in boiler to show the feed water is suitably treated.

Water treatment and oxygen attack can be combined by ensuring that the gasket is aligned correctly so that only the extreme edges of the gasket are exposed. If a new gasket leaks after fitting this is almost certainly due to incorrect sealing or excessive tightening, but such an action will seriously reduce the life of the gasket and cause problems later.

The lower handhole doors should be removed after one months and the interior of the boiler thoroughly examined. If the scale or sludge build-up is observed, a water treatment specialist should be consulted. 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.

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. This will allow the gasket material to contact naturally and follow the topography of the mating surfaces. The securing nut can then be tightened gently by, say, a quarter of turn to ensure a ‘snug’ fit and prevent the seal from being broken when the boiler is cold and under negative pressure.

Annually Repeat semi-annually maintenance. Pay attention to the percentage of CO2, O2, CO in the exhausted gas. It is recommended that the internal inspection interval is no more than 14 months. Weld inspection interval of 24 hours continuous operated boiler is depended on start times after last inspection (the boiler start from cold to W.P. is one time). The shell with front and rear head weld is 1 time every 5 years; and the longitudinal is 1 time every 10 years. More frequent inspection is needed for boilers always start form cold.

Gentle warming of the boiler on initial firing after maintenance will also help to ensure that the rubber curer to shape. If the rubber post-cures, the elastic memory will be destroyed and any initial over-tightening will cause the gasket to become hardened and embrittled, leading to cracks and eventual failure.

The annual inspection is carried out by competent professional personnel with necessary instrument.

Fitting New Gaskets

Fitting Instructions

TOPOG-E gaskets have a finite life after installation and must be replaced annually. It is important that the instructions given in this section are adhered to.

Blow down the boiler completely and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows. 1. Disassemble the crab 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.

The 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 last performance from your installation.

2. Place the new TOPOG-E gasket on the cover plate, ensure the gasket is the correct size and is 63

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.

Fig. 5-2 Illustration shows over compressed gasket 4. Gradually warm up the boiler, allowing steam pressure to make the seal. If the gaskets leaks during pressure build up, tighten the securing nut 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.

3. Position the cover plate in the boiler ring, ensuring that the plate is correctly centered. An off-center 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 and hand tighten the securing nut sufficiently to provide a snug fit. Tighten the nuts a further quarter of a turn using a spanner.

Note New gaskets fitted to inspection holes located along the bottom of the boiler are more difficult to install 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.

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 leakage at a later date.

5. Clean and check water gauge glass. Replace gasket for leakage.

Burner Maintenance Warning Any cover plates, enclosures, or guards anchored to the burner, or any burner related equipment, must remain in position at all times. Only during maintenance and service shutdown can these cover plates, enclosures, or guards be allowed to be removed. They must be replaced, and securely anchored before testing, adjusting, or running the burner related equipment.

Fig. 5-1 Illustration shows correct pressure on gasket

It is important that you provide support for the housing when in the operation to prevent damage to the hinges and subsequent components. 1. General A maintenance program avoids unnecessary down time, costly repairs, and promotes safety. It is recommended that a record be maintained of daily, weekly, monthly, and yearly maintenance activities.

64

No adjustment is required except proper positioning of the electrode wire.

Electrical and mechanical devices require systematic and periodic inspection and maintenance. Any automatic features do not relieve the operator from responsibility, but rather free from certain respective chores, providing time for upkeep and maintenance.

Flame Scanner The scanner must be clean. Even a small amount of contamination will reduce the flame signal. Wipe the scanner lens with a clean soft cloth.

Unusual noise, improper gauge reading, leak, sign of overheating, etc. can indicate a developing malfunction, requiring corrective action. D Series Impeller and Stator Cone Proper clearance between the impeller and the inlet housing and between the impeller and stator cone is not critical and is set at 1/8” nominal. When installing or removing the impeller, it is mandatory to use an impact wrench. Under No circumstances should you use anything other than an impact wrench. Inserting a bar through the impeller blade and using it as a lever will only damage the blade and also void the 5 year impeller warranty. If the impeller is changed to a different width, the stator cone position may require adjustment. This is provided for by means of slotted mounting holes in the blast tube. Loosen the three screws to reposition the cone. If a wide impeller is used to replace a narrower one, it may be necessary to trim the vanes for additional clearance.

Fig.5-3 Infrared Scanner

Firing Head Inspection Disconnect the damper linkage, release the impeller housing latch and swing the housing open for access to the firing head. Inspect the flame scanner lens to be sure it is clean and the support tube is in proper position to sight the flame through the hole in the diffuser. Inspect the lead wire to the ignition. It must be firmly attached and should be clean and free of cracks. The oil nozzle should be inspected periodically depending on the grade of oil burned and the cleanliness of the environment.

Fig 5-4 UV Scanner Oil Nozzle Successful burner operation requires use of the proper style nozzle tip and keeping the orifice clean. Standard nozzle tips furnished on the burners are of a special emulsifying type which insures proper mixing with the air steam. Unsatisfactory performance and loss of efficiency can result from the use of nonstandard nozzle tips. If the burner flame becomes stringy or lazy, it is possible that the spring is not properly in place or the nozzle is clogged. This problem is usually indicated by an abnormally high reading on the atomizing air pressure gauge on the air-oil tank. To remove the nozzle, disconnect the oil and air tubes to the nozzle tip and swirler. To clean the nozzle,

Pilot and Ignition Electrode The ignition transformer requires little attention other than making sure the ignition wire is firmly attached to the transformer and the electrode. Be sure the wire insulation is in good condition and not grounded. Failure to keep the ignition electrode clean and properly set can cause faulty operation. 65

unscrew the tip from the nozzle body. Use care not to distort the tube. Hold the nozzle body in a vise or use two wrenches, one on the body and one on the tip. Disassemble the nozzle tip. Carefully clean all parts in solvent and reassemble the nozzle. To insure proper atomizing, the tip must be screwed in tightly with the swirler seating spring pressing the swirler tight against the nozzle tip. Turn the swirler a few times to be sure it fits snugly in the nozzle and the spring is pressing the two parts firmly together. When reinstalling, be sure the nozzle is centered with the proper distance from the diffuser.

Note It is essential that the cam spring, cam follower arm at the pivot be greased sparingly every month to ensure smooth operation of the cam assembly. Regular automotive bearing grease should be used. Burner Mounting Inspection The seal between the burner flange and furnace front plate must not permit combustion gases to escape. Periodic inspection is important. Refer to the installation: the area between the outside circumference of the dry oven and existing refractory should be packed with Kaiser refractory MonoT-9 Airset or equal within two hours after coating the dry oven with Trowleze.

Caution Do not attempt to use wire or a sharp metal tool to clean the nozzle orifice as this will distort the fine orifice and ruin the nozzle. Use a sharp pointed piece of soft wood.

Fuel Oil System

Diffuser

Fuel Oil Circulating Pump

The diffuser is factory set and does not require attention under normal operating conditions. If fouled with carbon, the diffuser should be removed for cleaning. First remove the electrode and scanner leads, the gas pilot assembly, air and oil tubes and the diffuser. Mark the diffuser relative position to the blast tube, with a scribed or pencil line where the three mounting screws are located, to insure that the diffuser is placed back in the same position. Remove the three screws holding the diffuser to the blast tube and slowly pull the diffuser along the blast tube towards the firing head. Keep the diffuser as parallel as possible. If it should became stuck or tight, do not apply any tool which would distort the shape or blade configuration. A small wooden block tapped gently against the diffusers outer edge will help expedite its removal. Clean all carbon from the diffuser vanes and reinstall in reverse order of disassembly aligning the diffuser with the scribed marks. Do not attempt to drive the diffuser back along the blast tube with anything other than a small block of wood tapped against the diffuser’s outer edge. When reinstalling, be sure the diffuser is centered.

Failure of the circulating pump to deliver sufficient oil may be due to one of the following reasons: 1. Insufficient fuel oil in the storage tank. 2. Suction line or check valve clogged. 3. Air leaks or air traps in the suction line. If the line has a high point at which an air trap can occur, the line must be changed. 4. Oil strainer clogged(line strainer or burner strainer) 5. Suction line piping too small. 6. Three phase pump motor operating on single phase of fuse failure. 7. Pump rotating in wrong direction. 8. Low voltage applied to pump motor. D Series Air-oil Metering Pump Both the integral air-oil metering pump for light oil and the heavy oil metering pump are precisely fitted units employing a seal on the shaft to prevent oil leakage. Internal wear can take pace due to dirt in the oil and may in time result in excessive clearances, reducing pump capacity. Once adjusted, the pump will continue to operate with a minimum of readjustment. If burner failure appears to be caused by the metering pump, check the following:

Firing Rate Controls Check all rods and linkages. Make sure all connections are tight. Adjust if necessary. Readjust the burner if necessary.

1. See that the oil is at sufficient level in both fuel oil tank and air-oil tank on burner. 66

Never operate the compressor without the air cleaner in place. The cleaner should be cleaned at regular intervals. The correct oil level must be maintained in the air cleaner. Use the same oil used for air compressor lubrication.

2. Make sure all valves between the fuel oil tank are open. 3. Be sure the oil suction line is not air bound and check the suction line strainer. 4. Check the low fire setting of the metering pump to be sure it has not been disturbed. 5. Make sure the pump turns freely. 6. Inspect the burner oil nozzle for clogging.

Oil-Air Tank Check the lube oil level in the oil-air tank. Inspect oil level regularly as loss of oil will damage the compressor. Change oil every 2000 hours of operation. The oil-air tank should be drained once a year and thoroughly flushed. Remove the mist eliminator pads from the upper section of the tank, wash thoroughly in kerosene and dry. Refill with non detergent SAE 30 oil to a level midway up the sight glass. For normal environment use SAE30oil. For a 32 degree F. and below environment use SAE10 oil.

Whenever an oil metering pump fails to deliver full capacity or pressure , order a replacement pump at once and return the old pump for repair or exchange(where allowed). Primary Air Compressor The air compressor itself requires little maintenance, however its life is dependent upon sufficient clean, cool lubricating oil. The oil level in the air-oil tank must be checked regularly. Lack of oil will damage the compressor. Disassembly or field repairs to the air compressor are not recommended. Check the air-oil tank sight glass for proper oil level. The level should be kept at midpoint up the glass. The compressor rotor must turn freely. All tube connections must be air tight.

Oil Level Sight Gauge The oil level sight gauge can be cleaned by removing it from the air-oil tank and soaking it in a detergent solution. If cleaning the gauge proves unsatisfactory, replace it. Compressor Inlet Oil Strainer (Lube oil Strainer)

Alignment of the compressor and motor sheaves and proper belt tension are important.

The lube oil strainer prevents foreign materials from entering the compressor. The strainer screen must be cleaned at regular intervals.

Belt tension is adjusted according to the displacement on the belt with thumb pressure. The displacement should be 3/8 to 1/2 inch.

The screen is easily removed for cleaning by unscrewing the bottom plug. Immerse in solvent and thoroughly clean.

To adjust, loosen the two bolts on the compressor mounting flange and the three setscrews which hold the compressor in place.The mounting flange is slotted at the top, which permits belt tightening. If the slot in the mounting flange is insufficient for obtaining proper belt tension, the modular base has two extra holes for this purpose.

D Series Nozzle Line Heater Nozzle line heaters damaged by water accumulation, do not qualify for warranty or exchange service. Failure to prevent water accumulation inside the heater manifold constitutes improper care.

Move the top bolt to the next hole and adjust. Tighten bolts and setscrews. Replace belt guards. If belt becomes frayed or cracked, replace it.

Completely drain the heater manifold periodically. This should be part of the preventive maintenance program. Maintenance consists primarily of removing the heating element from the manifold and scraping any accumulation of carbonized oil or sludge deposits from the heat exchange surfaces.

Caution Do not attempt field repair the compressor. Installation of a new compressor is mandatory. Send the old compressor in for repair or exchange (where allowed)

Before breaking electrical connections to the heating elements, mark all wires and terminals to

Air Cleaner 67

Because of the many types of flame safeguard systems applicable to this equipment, complete descriptions of electrical systems are beyond the scope of this manual. An individual electrical schematic drawing is shipped with each burner and complete operation and troubleshooting instructions are available from the various flame safeguard system manufacturers.

assure correct replacement of wires. Periodic cleaning is necessary to prevent over heating or burn out of the elements. If operation of the heater becomes sluggish, examine the elements and clean as required. Inspect the manifold each time the heater is removed. Flush all accumulated sludge and sediment before reinstalling the heater. Heater must be full of oil before power is turned on.

Electric Motors Motor supply voltage must not more than 10 percent from nameplate ratings. At initial start-up and at least once a year thereafter, check the motor current with a meter while the burner is in high fire position. If the reading exceeds the nameplate rating plus service factor, determine the cause and correct it immediately. In dusty locations, clean the motor regularly to assure adequate cooling. Lubricate in accordance with the manufacturer’s instructions.

Oil Strainer Oil strainers should be cleaned frequently to maintain a free and full flow of fuel. The strainer screen must be removed and cleaned at regular intervals. The screen should be removed and cleaned thoroughly by immersing it in solvent and blowing it dry with compressed air. Light oil strainers should be cleaned each month. Heavy oil strainers should be checked and cleaned as often as the experience indicates the necessity.

Extended Shutdown

Gas System

When shutting down the burner for an extended period of time, the operator should use the following general guidelines to protect the burner from its surrounding elements. This will increase the operating life of the burner.

The burner output will increase with the reduction of pressure in combustion room if the gas actuator is damaged for mechanical or electrical accident.

1. Turn the main electrical disconnect switch to the burner to OFF. 2. Close all main fuel valves. 3. If the burner operates in a damp environment, cover it with plastic to protect all electrical components from moisture. Remove the flame safeguard control and store in a dry atmosphere. Fig 5-5 Gas Actuator Electric System

68

Maintenance Flow Chart Periodic Testing Recommended Check List Item

Frequency

Service by

Remarks

Gauges, monitors, and indicators

Daily

Operator

Make visual inspection and record readings in log

Instrument and equipment settings

Daily

Operator

Make visual against recommended specifications

Firing rate control

Weekly

Operator

Verify factory settings

Semi-annually

Service Technician

Verify factory settings

annually

Service Technician

Check with combustion teat

Flue, vent, stack, or outlet dampers

Monthly

Operator

Make visual inspection

Igniter

Weekly

Operator

Make visual inspection, check flame signal strength

Main

Weekly

Operator

Open limit switch, make sure valve close

Pilot and main gas or main oil

Annually

Service technician

Perform leakage test rrefer to instructions

Fuel valves

Combustion safety controls Flame failure

Weekly

Operator

Close fuel supply, chek safety shutdown

Flame signal strength

Weekly

Operator

Check flame signal reading on control display or test with meter-low and high fire.

Pilot turndown tests

As required/Annually

Service technician

Required after any adjustment to flame, scanner mount or pilot adjustment.

Refractory hold in

As

Service technician

See pilot turndown test instructions

70

Maintenance Flow Chart Periodic Testing Recommended Check List Item

Frequency

Service by

Remarks

Refer to boiler instructions-Slow drain test as per ASME pressure vessel code

required/Annually Low water fuel cutoff and alarm

Daily/weekly

Operator

Semi annually

Operator

High limit safety control

Annually

Service technician

Refer to boiler instructions

Operating control

Annually

Service technician

Refer to boiler instructions

Low housing, and damper position interlocks

Monthly

Operator

Refer to boiler instructions

Atomizing air steam interlock

Annually

Service technician

Refer to boiler instructions

High and low gas pressure interlocks

Monthly

Operator

Refer to boiler instructions

High and low oil pressure interlocks

Monthly

Operator

Refer to boiler instructions

High and low oil temperature interlocks

Monthly

Operator

Refer to boiler instructions

Fuel valve interlock switch

Annually

Service technician

Refer to boiler instructions

Combustion air purge switch

Annually

Service technician

Refer to boiler instructions

Burner position interlock

Annually

Service technician

Refer to boiler instructions

Low fire start interlock

Annually

Service technician

Refer to boiler instructions

71

Maintenance Flow Chart Periodic Testing Recommended Check List Item

Frequency

Service by

Remarks

Automatic changeover control(dual fuel)

At least annually

Service technician

Refer to boiler instructions

Safety valves

As required

Operator

In accordance to ASME pressure vessel code

Inspect burner component

Semi-annually

Service technician

Refer to boiler instructions

72

SECTION 6 TROUBLE SHOOTING

Problem Gas burner will not start

Cause

Remedy

Power supply

Check air flow switch in control panel Check fuses in control panel

Oil burner will not start

Scale or sludge build up on low water probe

Check low water probe for scale

Loose wire connection

Check connections to all components

Gas supply

Check gas pressure

Gas pressure switch

Ch k i ki Check gas pressure

Steam pressure switch

R t it h Check steam pressure switch

Boiler water not at normal

Ch k bl d th l Check boiler water indication

Reset low water controller

l

d

Main fuel valve not full closed(for FBC 400)

Check main fuel valve

Power supply

Check air flow switch in control panel

Scale or sludge build up on low water probe

Check low water probe for scale

Loose wire connection

Check connection s to all components

Gas supply

Check gas pressure

Gas pressure switch

Ch k i ki Check gas pressure

Steam pressure switch

R t it h Check steam pressure switch

Temperature control switch (for hot water boiler and heavy oil boiler) Boiler water not at normal

73

it h

and position switch

Reset low water controller

Ch k bl d th l l d Reset temperature protection button

Check boiler water indication

it h

Problem

Blower auto stop after gas burner start 5 seconds

Cause

Remedy

Main fuel valve not fully closed(for FBC 400)

Check main fuel valve and position switch

Air pressure switch not act

Check air pressure protection switch (In normal condition, the switch contact should close while blower pre purge.)

protection

Gas pressure switch not close

Check gas pressure switch

Temperature control switch action(for heavy oil heater)

Check temperature switch

Oil pressure close

Check oil pressure switch

switch

not

Reset gas high/low pressure protection

Reset temperature protection switch

Reset oil pressure protection button (in normal condition, the oil pressure switch contact close.)

Not enough air pressure from compressor

Check compressor and air protection switch (In normal condition, the pressure protection contact should be closed)

The blower purge at big damper but not do the next

The big damper feedback contact does not act

Adjust damper feedback block( the block is at the center rod of damper)

The blower purge at little damper but not do the next

The little damper feedback contact does not act

Adjust damper feedback block and related cam(the cam is in serve motor)

Boiler will not ignite

Ignition electrode dirt or crack

Clean ignition electrode and check crack

Dirty or damaged scanner

Use clean cotton and check signal voltage (in normal condition, it is 5v)

Incorrect distance of ignition electrode

Adjust distance( in normal condition, the distance between electrode and steel rod is 3-5mm)

Manual valve in ignition line is not open or the fuel exhausted

Open manual, replace gas bottle.

74

Problem

No reason shut during operation

down

Boiler will not maintain pressure

Wet stream

Pump will not cut off

Cause

Remedy

Ignition transformer burn out

Meter transformer resistance ( in normal condition, the primary resistance is about 20 and the second is about 1000.

Ignition damper too big

Consult professional adjustment

Normal

The set steam pressure is reached, boiler will auto start while pressure is less than setting.

Scanner trouble

Clean with cotton cloth and check signal voltage(in normal condition, signal voltage is 5V)

Fuel shut during operation

Check fuel supply

Not enough gas pressure (gas boiler)

Check gas pressure, notify Gas company

Gas supply

See above

Oil supply

See above

Steam pressure switch

Check steam pressure switch, readjust or replace

Scale build up in boiler

Check water treatment advisor

Steam traps

Check steam traps and replace as necessary

Dirty flue

Clean flue side of boiler

Steam overload

Reduce

Too much chemical

treatment

personnel

for

Dump return tank, flush system or stop treatment for a week.

Too high water level

Drop boiler water(in normal condition, boiler water should be in middle of the glass sight.

Earth connection

Check for tightness and clean

75

Problem

Feed pump runs but does not put water into boiler

Feed pump will not start in time

Low water alarm /burner shut off will not act in time

Cause

Remedy

Probe connection

Check for tightness and clean

Dirty probes

Clean or replace

Water level relay damaged

Replace

Air/steam lock in pump

Check For Bad Steam Traps

Blocked water feed line

Ch k f h k l i t f Check and clean if necessary

Impellers damaged

Replace pump

Probe connections

Check for tightness and clean

Dirty probes

Clean or replace

Water level relay damaged

Replace

Earth connection

Check for tightness and clean

Probe connections

Check for tightness and clean

Dirty probes

Clean or replace

Water level relay damaged

Replace

Earth connection

Check for tightness and clean

d li

Other troubles: The boiler program control is Honeywell 7800 with automatic self check. If user chose the display, it will bring about convenience and provide information for the service personnel, the following table is the program trouble information: Honeywell 7800 trouble information Fault Number

Annunciation Message

Description

Fault 1

*No Purge Card*

Purge card problem.

Fault 2

*AC Frequency/Noise*

Lockout due to inability to take minimum number of samples.

76

Fault Number

Annunciation Message

Description

Fault 3

*AC Line Dropout*

Lockout due to AC line dropout detected

Fault 4

*AC Frequency*

Lockout due to AC line frequency too fast.

Fault 5

*Low Line Voltage*

Lockout due to insufficient AC line voltage.

Fault 6

*Purge Card Error*

Purge card parity is bad.

Fault 7

*Flame Amplifier*

Flame sensed when checked for ampli-check system.

Fault 8

*Flame Amp/shutr*

Flame sensed when checked for shutter-check system.

Fault 9

*Flame Detected*

Flame detected during Standby and time limit has expired.)

Fault 10

*Preignition ILK*

Fault 13

*Airflow Sw. On*

Preignition interlock open during Standby and time limit has expired. Airflow switch shorted and limit has expired in Standby(demand was present)

Fault 14

*High Fire Sw*

High Fire switch open and time limit has expired during prepurge.

Fault 15

*Flame Detected*

Fault 17

*Main Flame Fail*

Flame sensed when shutter open and no flame is expected during Standby. Main flame failure during Run after flame has been on for a while.

Fault 18

*Flame Detected*

Fault 19

*Main Flame Ign.*

Fault 20

*Low Fire Sw. Off*

Flame detected during Purge or Waiting, when no flame should exist. Flame loss detected, main flame did not ignite or failed during first 10s of Run Low Fire switch open time limit has expired during Waiting.

Fault 23

*Airflow Switch*

Combustion airflow interlock fault during Waiting.

Fault 24

*Internal Fault*

Flame interlock is enabling fuel valves and no flame is present.

Fault 25

*Internal Fault*

Flame interlock feedback indicates it is not enabling main valve.

Fault 28

*Pilot Flame Fail*

Pilot flame failure.

Fault 31

*Low Fire Sw. Off*

Low fire interlock switch failed to close during Run.

Fault 32

*Airflow Switch*

Airflow switch failed to make or opened.

Fault 33

*Preignition ILK*

Preignition interlock opened

Fault 35

*Internal Fault*

Safety relay feedback showed off when it should be on.

77

Fault Number

Annunciation Message

Description

Fault 36

*Internal Fault*

Main valve relay feedback showed off when it should be on.

Fault 37

*Internal Fault*

Pilot valve relay feedback showed off when it should be on.

Fault 38

*Internal Fault*

Ignition relay feedback showed off when it should be on.

Fault 39

*Internal Fault*

Pilot valve 2 relay showed off when it should be on.

Fault 40

*Internal Fault*

Safety relay feedback on when it should be off.

Fault 41

*Main Valve On*

Main valve relay feedback showed on when it should be off.

Fault 42

*Pilot Valve 1 On*

Pilot valve relay feedback showed on when it should be off.

Fault 43

*Ignition On*

Ignition relay feedback showed on when it should be off.

Fault 44

*Pilot Valve 2 On*

Pilot valve 2 relay feedback showed on when it should be off.

Fault 45

*Low Fire Sw. Off*

Low fire switch opened.

Fault 46

*Flame Amp Type*

Type and/or FFRT changed since initial read.

Fault 47

*Jumpers Changed*

Field jumpers have changed since initial read.

Fault 50

*Jumpers Wrong*

Illegal jumper combination selected (as defined by the burner sequence).

Fault 51

*Flame Too Strong*

Measured flame signal is to strong.

Fault 52

*Internal Fault*

Pilot valve 2 relay feedback showed off when it should be on.

78

SECTION 7 WARRANTY 3 Year Conditional Warranty On the Fulton Boiler Pressure Vessel Fulton China LLC will repair or replace F.B factory any Fulton pressure vessel, which, within 3 years of the date of sale from factory, is found of be defective in workmanship or material, provided this equipment is installed, operated and maintained by the buyer in accordance with the Fulton instruction manual and approved practices, and that the water quality used in the system has been regularly checked to meet the standards for ideal and proper boiler feed water during the warranty period. This warranty does not cover damage or failure that can be attributed to corrosion, (including oxygen pitting) scale or dirt accumulations, or lack of water conditions. The warranty does not include labor charges of any kind. In the event a failure reported. Fulton will require an analysis of the boiler feed water to determine that acceptable water conditions are present at the installation site as well as documentation on the feed water treatment employed since the installation of the boiler. Consult Fulton China LLC Feed water treatment and proper daily blow down procedures are very important in keeping your boiler heating surface free of scale formation, pitting, oxygen corrosion and foaming or bouncing water. Suitable feed water treatment will prolong the boiler life. A thorough boiler inspection should take place during the first three months of operation to access the effectiveness of boiler water treatment techniques, including analysis of potential oxygen pitting. It is the owner’s responsibility to assure safe operation of the boiler. To avoid corrosion, scale or dirt accumulations, it is recommended that a daily blow down procedure be instituted. The boiler power should be left on during daily blow down so that correct operation in the low water relay may be checked. While blow down, the boiler pressure will drop significantly. While blowing boiler down with power on, it is normal to hear the boiler feed pump come on. The burner should no turn on. If the burner does come on, turn the boiler off and contact our factory immediately. Corrosive acid and chlorine based chemicals in the atmosphere can be damaging to this boiler. It is the owner’s responsibility to have the boiler room periodically tested to assure these damaging chemicals are not present.

1 Year Standard Warranty A Fulton China LLC will warranty other part which within 1 year of the date of sale from factory is found to be defective in workshop or material, provided the equipment has been installed, operated and maintained by the buyer in accordance with the operating instruction manual provided with the equipment and generally accepted approved practices, and on the provision that the buyer gives proper notification in writing as soon as the defect becomes apparent, and that he has properly filled out and returned his warranty card. Fulton will in charge of repair or replace the original equipment without any pay. This warranty does not include labor charges of any kind.

B Fulton China LLC does not provide any warranty for parts manufactured by others. 79

C The working voltage of electrical controls in Fulton boiler should be 110V +/-10%. If the user does not ensure the constant voltage, install constant voltage power. Otherwise the electrical element damage caused by not required voltage will not within the warranty.

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