FULTON FB-S series Instruction manual

FULTON BOILER
FB-S SERIES
INSTALLATION, OPERATION & MAINTENANCE MANUAL

Fulton Boiler FBS Series
1 FBS 01/05
Introduction
This operating manual presents information that will help to properly operate and care for the
equipment. Study its contents carefully. The unit will provide good service and continued operation if
proper operating and maintenance instructions are followed. No attempt should be made to operate
the unit until the principles of operation and all of the components are thoroughly understood. Failure
to follow all applicable instructions and warnings may result in severe personal injury or death.
These instructions must not be considered as a complete code of practice, nor should they replace
existing codes or standards which may be applicable.
The requirements and instructions contained in this section generally relate to the standard Fulton
boiler model FBS. When installing a packaged unit, this entire section should be read to ensure that
the installation work is carried out correctly.
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) ASME welding inspection.
d) ASME hydrostatic test inspection.
e) Electrical components inspection.
f) Operating test.
g) Final engineering inspection.
h) Crating inspection.
NOTE
The installation of the Fulton Boiler should be carried out by competent personnel in
accordance with the standards of the National Fire Protection Association. All state and
jurisdictional codes beyond the scope of the applicable ASME boiler and pressure vessel
codes, for its corresponding classification, should be followed in all cases. Jurisdictional
authorities must be consulted prior to installation.
All units are crated for fork lift transport. Once uncrated, all units can be transported with a forklift.
Under no circumstances should weight be allowed to bear on the jacket., control panel, or fan
housing of any Fulton Boiler.
The customer should examine the boiler for any damage, especially the refractories.
Rigging your boiler into position should be handled by a competent rigger experienced in handing
heavy equipment.

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CONTENT
1 Safety Warnings & Precautions
2 Description & Introductions
General
Specifications & Dimensions
3 Installation
Locating the Boiler
Boiler room ventilation
Flue and chimney requirements
Water supply
Valves
Electrical Requirements
Gas Supply
Oil Supply
Installation check points
Cleaning
Boil-out of new unit
4 Controls & Burner
Boiler Control panel
Burner
5 Operation
Fitting the boiler
Starting the burner
Daily operating test
Bolwdown procedure
To shutdown the burner
Evaporation test
Fault finding
6 Maintenance
General
Weekly
Six monthly
Annually
Fitting new gasket
7 Warranty

Fulton Boiler FBS Series
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SECTION 1
Safety warnings & Precautions
The following WARNINGS, CAUTIONS, and NOTES appear in various chapters of this manual.
They are repeated on these safety summary pages as an example and for emphasis.
WARNINGS must be observed to prevent serious injury, or death to personal.
CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating
effectiveness.
NOTES must be observed for essential and effective operating procedures, conditions, and as a
statement to be highlighted.
It is the responsibility and duty of all personnel involved in the operation and maintenance of this
equipment to fully understand the WARNINGS, CUATIONS, and NOTES by which hazards are to
be reduced or eliminated. Personnel must become thoroughly familiar with all aspects of safety and
equipment prior to operation or maintenance of the equipment.
WARNING
Do not operate, service, or repair this equipment unless you fully understand all
applicable sections of this manual.
Do not allow others to operate, service, or repair this equipment unless they fully
understand all application sections of this manual.
Failure to follow all applicable warnings and instructions may result in severe personal
injury or death.

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Section 2
Description & Introductions
General
Fulton boiler standard FB-S model is a three-pass, wet back, and corrugated furnace design steam
boiler. In the first pass, the flame and high temperature flue gas flows from the front to the back of the
furnace; Though the second pass pipes, high temperature flue gas flows from the combustion furnace
to the front chamber; In the third pass, the flue gas passes through the third pass pipes to the back of
the boiler stack and vents out. Corrugated furnace highly increases the heat exchange area, heat
transfer efficiency and reduces the possible damage to the boiler durability caused by heat expansion
and cold contraction.
Boiler is designed and manufactured to comply with BS code and Chinese Boiler Standard, with
maximum working pressure of 1.0MPa (150PSI) or 1.25MPa (180PSI).
The fully packaged boiler has passed the strict test before it is delivered to the customer. The
equipment will give long life and excellent service on the job if proper operating and maintenance
instructions are followed.
FB-S boiler is a cylindrical vessel, with horizontal tubes passing through and connected to the front
and rear tube sheets. The vessel contains the water and absorbs the energy generated from the
flame. The front door and rear door provide the seal to contain the hot combustion gasses. Baffles
designed into the doors serve to redirect the combustion gasses through the various firetube
passages. The flame originates in the furnace. As the combustion gasses travel down the furnace
and through the various firetube channels, heat from the flame and combustion gasses is transferred
to the water. Transferred energy develops into the required steam or hot water.
The front door and rear door make it is easy to clean the combustion chamber. The pressure vessel
can be inspected and repaired by the manhole on the top and handholes on the side or bottom.
The general information in this manual applies directly to boilers in sizes ranging from 1 ton/hr
through 6 ton/hr steam output boiler for the following fuels:
Gas
No.2-6 Oil
No.2 Oil and Gas
Boiler equipped with fully automatic burner for two-stage operation, the fully modulating burner can
be supplied on customer’s requirement.

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Specifications & Dimensions
Specifications
Model FB-S 1-1.0 1.5-1.0 2-1.0 3-1.0 4-1.0 4-1.25 6-1.25
Nominal steam output

T/h

1.0 1.5 2.0 3.0 4.0 4.0 6.0
Operating pressure

MPa

1.0 1.0 1.0 1.0 1.0 1.25 1.25
Operating steam temperature


184 184 184 184 184 194 194
Inlet water temperature


20 20 20 20 20 20 20
Water pump electric power (Kw) 2.2 2.2 2.2 3.0 3.0 4.0 5.5
Maximum fuel consumption
Light oil (Kg/h) 60.9 91.4 121.8 182.7 243.6 244.4 365.6
Heavy oil (Kg/h) 62.2 93.3 124.4 186.6 248.8 249.7 374
Natural gas (m
3
/h) 76.6 114.9 153.2 229.8 306.4 315.3 445
Town gas (m
3
/h) 189.4 284.1 378.8 568.2 757.6 778.7 1099.1
Note: 1) All steam output (kg/hr) ratings from 0 MPa at 100 , fuel consumption based on light oil 1,1200 Kcal/kg, heavy oil

10,960 kcal/kg, nature gas 8,900 kcal/m
3
, town gas 3600kcal/m
3
.
2) Specification and dimensions are approximate, the Fulton Companied reserve the right to change specifications or
dimensions.
Connection
Model FB-S 1-1.0 1.5-1.0 2-1.0 3-1.0 4-1.0 4-1.25 6-1.25
Main steam valve DN50 DN65 DN65 DN100 DN100
DN100 DN125
Safety valve DN40 DN40 DN40 DN50 DN50 DN50 DN80
Water inlet valve DN40 DN40 DN40 DN40 DN40 DN40 DN50
Drain valve DN40 DN40 DN40 DN50 DN50 DN50 DN50
Flue diameter (mm) 300 350 400 450 500 500 600
Water gauge outlet DN15 DN15 DN15 DN15 DN15 DN15 DN15
Note: 1) The connections of steam valve, safety valve and blow-down valve are all flange connections.
2) If the burners and /or pumps are different, the boiler electrical usages are also different, please based on the finally
drawings.
3) Specifications and dimensions are approximate. The Fulton Companies reserve the right to change specifications
and dimensions.

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Section 3
Installation
General
NOTE
It is essential that the installing shall be undertaken only by suitably qualified and
experienced personnel. And it should comply with appropriate Codes and Standards.
Locating the Boiler
A) The boiler should be closed in dry surroundings on a level base, making sure that there is
sufficient room around the boiler to enable the operator and/ or the maintenance engineer to
gain access to all parts of the boiler. Check location for ease of water supply and electrical
connections.
B) Place the boiler on a non-combustible floor with clearances to unprotected combustible
materials, including plaster or combustible supports.
C) It is necessary to have enough clearance from the floor to the ceiling for removing of the
burner and have the following clearance from boiler for servicing:
Dimensions of the boiler and the necessary clearance
Model FB-S 1-1.0 1.5-1.0
2-1.0 3-1.0 4-1.0 4-1.25 6-1.25
Total length(mm) 3324 3624 4072 4772 4956 4956 5540
Total width(mm) 1705 1785 2100 2196 2170 2170 2700
Total height(mm) 1955 2040 2335 2490 2542 2546 3000
For pipe changing(mm) 3300 3300 4300 4500 4700 4700 5300
Front of boiler(mm) 3000 3000 3000 3000 3000 3200 3200
Two sides of boiler(mm) 1500 1500 1500 1500 1500 2000 2000
Back of boiler(mm) 1500 1500 1500 1500 1500 2000 2000
Boiler Room Ventilation
A) It is most important to provide free access of air to the boiler. To burner fuel properly, it
requires one square inch opening of fresh air for every 3,000 BTU input of fuel. (6.4cm
2
for
every 56 Kcal).
B) Proper ventilation of the boiler room is essential for good combustion. Install two make up air
openings, one at a low level (24” or 610mm from floor) and one at a higher level in the boiler
room wall. This will provide a flow of air to exhaust the hot air from the boiler room.
C) The following openings are the recommended for each size boiler:

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Recommended minimum opening
Model FB-S 1-1.0 1.5-1.0 2-1.0 3-1.0 4-1.0 4-1.25 6-1.25
Minimum area (m
2
) 0.7 1.0 1.5 2.1 3.0 3.2 4.5
Be sure total BHP= proper make up air opening size. For instance if you have three 300 BHP boilers,
it is a total BHP of 900, and the 900 BHP make up air opening size is recommended.
NOTE
These measurements are subject to state and local regulations. The installation of exhaust
fans in a boiler room is not recommended. An exhaust fan can create down draft in the stack
or restrict the burner’s air supply which will result in poor combustion. It is essential that only
fresh air is allowed to enter the combustion air system. Foreign substances, such as
combustible volatiles and lint, in the combustion system can create hazardous conditions.
Flue and Chimney Requirements
A) The flue from the appliance and the joint between this flue and the chimney are sealed to prevent
leakage of combustion products.
B) The top of the flue or chimney shall be higher than any roof within a radius of 10 meters.
C) Checks are made to ensure that the chimney is suitable for burner and that the proposed
installation complies with the local authority and other regulations covering such installations.
D) If more than one appliance is connected to a common flue or chimney the cross-section of the
chimney should be adequate for the total volume of combustion products from the appliances.
E) The total horizontal run of the boiler flue should not exceed 25% of the total vertical rise. There
should have a angle more than 15 degrees for the horizontal run. Reducing the resistance of the
combustion products and avoid rusting by accumulating condensation in flue.
F) The installer should check the draft with a meter at -.02-.04” W.C. pressure (-0.508 to -1.016mm)
with the burner off. If the pressure is too low, a balancing damper should be located close to the
flue outlet to regulating the pressure of the draft.
Water Supply
A. General
The operator should be familiar with this part before attempting to place the unit into operation.
Although it is of prime importance, the subject of water supply and treatment cannot adequately be
covered in this manual. For specific information or assistance with your water treatment requirements,
contact your boiler service and parts representative.
Feed water equipment should be checked and ready for use. Be sure that all valves, piping, boiler
feed pumps, and receivers are installed in accordance with prevailing codes and practices.
Water requirements for steam boilers are essential to boiler life and length of service. It is vital that
care be taken in placing the pressure vessel into initial service. The waterside of new boilers and new
or remodeled steam or hot water systems may contain oil, grease or other foreign matter. A method of
boiling out the vessel to remove the accumulations is described later in this part.
Boilers, as a part of a hot water system, require proper water circulation. The system must be
operated as intended by its designer in order to avoid thermal shock or severe, possibly damaging,
stresses from occurring to the pressure vessel.
B. water treatment
Feed water contains solids and dissolved gases. These may promote incrustation of scale; foaming,
priming, surging, and solids in steam; corrosion and pitting; or caustic embrittlement. To prevent this,
feedwater must be studied individually and treated accordingly by reputable professionals
specializing in this field. It is strongly recommended that a competent water treatment company be

Fulton Boiler FBS Series
FBS 01/05 8
consulted prior to the installation of the boiler.
The purpose of this treatment should be to provide quality feedwater to the boiler such that corrosion
and deposition in the boiler will be minimized. Dissolved oxygen, high chloride levels and low PH can
all be major causes of corrosion. Untreated hardness is the major cause of deposits. Poor quality
feedwater requires increased blow off and increased chemical treatment cost to prevent boiler
corrosion and scaling.
The Fulton warranty does not cover damage or failure that can be attributed to corrosion,
scale or dirt accumulations. Oxygen is a corrosive. See the warranty section of this manual for full
details.
Following are recommendations for feed water and boiler water. Contract your local water
treatment professional for testing and treatment recommendations. It is very important that a
strict water treatment program be followed.
Feed water
Total dissolved solids ……………………..

5 mg/l
Hardness .…………………………………

0.03mmol/l
PH Valve…………………………………….

7 (25

)
Dissolved Oxygen…………………………

0.1 mg/l
Oil ……………………………………………

2 mg/l
Boiler water
Total Alkalinity ……………………………..6-26 mmol/l
PH Valve…………………………………….10-12 (25

)
Dissolved Oxygen………………………….none
Properly treated boiler feed water, coupled with good engineering and operating practices, lead to
maximum effectiveness and long trouble-free life of pressure vessels, at the lowest operating cost.
Contact your local authorized boiler representative for information on how to prevent the presence of
unwanted solids and corrosive gases.
Accomplishment of the above objectives generally requires proper feed-water treatment before and
after introduction of the water into the boiler. The selection of pre-treatment processes depends upon
the water source, its chemical characteristics, amount of makeup water needed, plant operating
practices, etc. Treating methods filtering, softening, de-mineralizing, deaerating, and preheating.
After-treatment involves chemical treatment of the boiler water.
Because of the variables involved, no single boiler compound can be considered a “cure-all” nor is it
advisable to experiment with homemade treating methods. Should recommendations and their
employment should be augmented by a periodic analysis of the feed-water, boiler water, and
condensate.
The internal or waterside surfaces of the pressure vessel should be inspected with enough frequency
to determine the presence of any contamination, accumulations of foreign matter, or corrosion, and/or
pitting. If any of the conditions are detected, contact your local authorized boiler representative for
advice on corrective action.
A properly sized water meter should be installed in the raw water make-up line in order to accurately
determine the amount of raw water admitted to the boiler (steam or hot water) and to aid in
maintaining proper waterside conditions.
Valves
A) Pressure gauge
The Pressure gauge is above the panel box which installed on the right hand of the boiler. A
three-way valve is fitted with the pressure gauge, to assist drain off regularly.

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B) Main steam valve
The main steam valve is installed on the top of the boiler. It will be connected with the steam pipework
to all kinds of equipments which consume steam. There should be enough outlet for drain off and
flush in the pipework.
C) Safety valve
The safety valve is installed on the top of the boiler. Its setting was finished by the manufacturer
before delivery; do not attempt to change the setting without permission of Fulton or authority. The
function of the safety valve is avoid the pressure in the boiler exceed the design value. Any
equipment connect with the boiler should can run under the boiler pressure. If not, another safety
valve must be used for protecting it.
CAUTION
The safety valve supplied by manufacturer can only protect the boiler, it can not protect any
other equipments in the system.
D) Water level gauge
Two plate water level gauges are equipped to Fulton boiler FB-S model. Boiler operator can see the
water level in side the boiler from these gauges. Both of them are connected to a 1/4” copper pipe
which drain water can flow through to assistant pipework.
Electrical Requirements 
A) Connect wiring as shown in the wiring diagram which is furnished inside the electrical control
panel box.
B) Electrical power available is usually 230/460 volt, 3 phase, 60 HZ or 380 volt, 3 phases, 50 HZ.
Gas Supply
Natural gas is the standard gas for the gas boiler. Special requirements on request- i.e. liquid
petroleum gas, town gas.
Gas must be supplied at a pressure high enough to overcome the pressure loss in the burner gas
train and furnace while running at full input. This pressure is different from the kinds of the burner
used for the boiler. On FB-S1-1.0 to FB-S3-1.0, the pressure of supply gas is 50-100 mbar.; on
FB-S4-1.0 to FB-S6-1.25, the pressure of supply gas is 100-130 mbar, the pressure must be checked
and make sure it is high enough. If it is too low, a gas booster must be used in the gas supply system.
When a gas booster is used, the gas pressure at the booster inlet must not fall below 100 mbar. The
booster should be installed as near to the burner as possible. 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.
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. It should be of
sufficient size to satisfy the pressure and volume flow requirements of the burner under all firing
conditions. Checks should be made to ensure that all meters and other components are appropriately
rated for the maximum gas flow rate anticipated.
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 bruner control train in order to avoid any restriction in gas flow.

Fulton Boiler FBS Series
FBS 01/05 10
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. Fulton Companies can accept no responsibility for consequential loss, damage or
personal injury which results from a failure to follow the manual.
Oil Supply
The oil supply pipework to the boiler must be appropriate to local conditions and must be constructed
and installed in compliance with appropriate Codes and Standards. It should be of sufficient size to
satisfy the pressure and volume flow requirements of the burner under all firing conditions. Checks
should be made to ensure that all meters and other components are appropriately rated for the
maximum oil flow rate anticipated. Galvanized steel pipe should not be used. The supply pipework
should include an appropriate filter.
A) 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. A oil filter must be installed before the oil circulating pump, recommend less than 60
Mesh.
B) The final connection to the oil pump inlet should be made using the flexible pipes supplied with
the burner.
C) One gate valve should installed to the inlet and outlet of the circulating pump separately. A
pressure gauge (0-60psi) is needed also to the outlet.
D) It is important to ensure that the return pipe is not obstructed as this may result in damage to the
pump.
E) In the case of heavy oil (No.4, No.5, and No.6 oil) the pipework and oil storage tank should be
insulated trace heated and thermostatically controlled.
Refer to the details in the BURNER section
Installation Check Points
A) Make sure that all piping connections are complete and tight.
B) Make sure the pressure controls are adjusted properly.
C) Make sure all electrical connections in the control box, the water column, and elsewhere are
secure.
D) Make sure the door in the boiler room is closed. Combustion air contaminates can cause damage
to the boiler jacket and stack.
Before operating pumps, metering heads and compressors, make certain that reservoirs are properly
filled with the specific lubricant. Open all necessary oil shut-off valves. Do not run compressors,
pumps, or metering units without oil.
Before connecting electrical current to any component, be sure the supply voltage is the same as that
specified on the component nameplates.
Make certain that the operator in charge is properly instructed in the operation and maintenance
procedures.
NOTE
The pressure vessel must be cleaned before running the boiler after installation

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Cleaning
ASTEAM PIPING
Steam and water piping systems connected to the boiler may contain oil, grease, or foreign matter.
The impurities must be removed in order to prevent damage to pressure vessel heating surfaces. On
a steam system, the condensate should be wasted until tests show the elimination of undesirable
impurities. During the period that condensate is wasted, attention must be given to the treatment of
the raw water used as make-up so that an accumulation of unwanted materials or corrosion does not
occur. For more information, contact your local authorized boiler representative.
On a hot water system, chemical cleaning is generally necessary and the entire system should be
drained after treatment. Consult your local authorized boiler representative for recommendations,
cleaning compounds, and application procedures.
BPRESSURE VESSEL
The waterside of the pressure vessel must be kept clean from grease, sludge, and foreign material.
Such deposits, if present, will shorten the life of the pressure vessel, will interferer with efficient
operation and functioning of control, of safety devices, and quite possibly cause unnecessary and
expensive re-work, repairs, and down-time.
The installation and operating conditions that the boiler will be subjected to should be considered and
cleaning of the waterside of the pressure vessel should be provided during the course of initial
start-up.
The pressure vessel and the steam and return lines or hot water piping represent, in effect, a closed
system. Although the steam and return (condensate) lines or hot water piping system may have been
previously cleaned, it is possible that:
(1) Cleaning has been inadequate.
(2) Partial or total old system is involved.
(3) Conditions may prevent adequate cleaning of piping.
The pressure vessel waterside should be inspected on a periodic basis. An inspection will reveal true
internal conditions and serve as a check against conditions indicated by chemical analysis of the
boiler water. Inspection should be made three months after initial starting and at regular 6-, 9-, or
12-month intervals thereafter. The frequency of further periodic inspections will depend upon the
internal conditions found.
If any unwanted conditions are observed, contact your local authorized boiler representative for
recommendations.
Any sludge, mud or sediment found will need to be flushed out. If excessive mud or sludge is noticed
during the blowdown the scheduling or frequency of blowdown may need to be revised. The need for
periodic draining or washout will also be indicated.
Any oil or grease present on the heating surfaces should be removed promptly by a boil-out with an
alkaline detergent solution.
NOTE
Temperature of initial fill of water for hydrostatic tests, Boil-out, or for normal operation
should be as stated in the ASME Boiler Code.

Fulton Boiler FBS Series
FBS 01/05 12
Boil-out of New Unit
The internal surfaces of a newly installed boiler may have oil, grease or other protective coatings
used in manufacturing. Such coatings must be removed because they lower the heat transfer rate
and could cause over-heating of a tube. Before boiling out procedures may begin, the burner should
be ready for firing. The operator must be familiar with the procedure outlined under burner operation.
WARNING
Use of a suitable face mask, goggles, rubber gloves, and protective garments is strongly
recommended when handing or mixing caustic chemicals. Do not permit the dry material or
the concentrated solution to come in contact with skin or clothing. Failure to follow these
instructions could result in serious personal injury or death.
Your local authorized boiler representative will be able to recommend a cleaning or boil-out
procedure. In the event such service is unavailable or is yet unscheduled, the following information
may be of assistance.
There are several chemicals suitable for boil-out. One combination often used is soda ash (sodium
carbonate) and caustic soda (sodium hydroxide) at the rate of 3 to 5 pounds each per 1.000 pounds
of water, along with a small amount of laundry detergent added as a wetting agent.
The suggested general procedure for cleaning a boiler is as follows:
(1) Have sufficient cleaning material on hand to complete the job.
(2) When dissolving chemicals, the following procedure is suggested. Warm water should be put into
a suitable container. Slowly introduce the dry chemical into the water, stirring it at all times until the
chemical is completely dissolved. Add the chemical slowly and in small amounts to prevent excessive
heat and turbulence.
(3) An over-flow pipe should be attached to one of the top boiler openings and routed to a safe point
of discharge. A safety valve tapping is usually used.
(4) Water relief valves and steam safety valves must be removed before adding the boil-out solution
so that neither it nor the grease which it may carry will contaminate the valves. Use care in removing
and reinstalling the valves.
(5) All valves in the piping leading to or from the system must be closed to prevent the cleaning
solution from getting into the system.
(6) Fill the pressure vessel with clean water until the top of the tubes are covered. Add the cleaning
solution and then fill to the top. The temperature of the water used in the initial fill should be at
ambient temperature.
(7) The boiler should then be fired intermittently at a low rate sufficient to hold solution just at the
boiling point. Boil the water for at least five hours. Do not produce steam pressure.
(8) Allow a small amount of fresh water to enter the boiler to create a slight overflow that will carry off
surface impurities.
(9) Continue the boil and overflow process until the water clears. Shut the burner down.
(10) Let the boiler cool to 120

or less.
WARNING
Be sure to drain the hot water to a safe point of discharge to avoid scalding. Failure to follow
these instructions could result in serious personal injury or death.
(11) Remove hand-hole plates and wash the waterside surfaces thoroughly using a high pressure
water stream.
(12) Inspect the surfaces. If they are not clean, repeat the boil out.
(13) After closing the hand-holes and reinstalling the safety or relief valves, fill the boiler and fire it

Fulton Boiler FBS Series
13 FBS 01/05
until the water is heated to at least 180

to drive off any dissolved gases, which might otherwise
corrode the metal.
The above procedure may be omitted in the case of a unit previously used or known to be internally
clean. However, consideration must be given to the possibility of contaminating materials entering the
boiler from the system.
On a steam system, the condensate should be wasted until tests show the elimination of undesirable
impurities. During the period that condensate is wasted, be sure make-up water is treated to prevent
an accumulation of unwanted materials or corrosion.
Washing Out
No later than three months after initially placing the boiler into operation and starting service, and
thereafter as conditions warrant, the pressure vessel should be drained after being properly cooled to
near ambient temperature. Hand-hole covers should be removed and waterside surfaces should be
inspected for corrosion, pitting, or formation of deposits.
Flushing of Pressure Vessel Interior
Upon completion of the inspection, the pressure vessel interior should be flushed out, as required,
with a high pressure hose. If deposits are not fully removed by flushing, a consultation may be
required with your local authorized boiler representative. In extreme cases, it may be necessary to
resort to acid cleaning. Professional advice is recommended if acid cleaning is required.
The inspections will indicate the effectiveness of the feed-water treatment. The effectiveness of
treatment, the water conditions, and the amount of fresh water make-up required are all factors to be
considered in establishing frequency of future pressure vessel washouts. Contact your local
authorized boiler representative for more information.

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FBS 01/05 14
Section 4
Controls & Burner
The following brief description of the fittings and controls used on the FB-S boiler is intended to
provide the operator with a basic understanding of the operating principles, which is essential for the
continued efficient use of the boiler.
1. Boiler Control Panel
Boiler controls and indicators are housed in a control panel mounted on the side of the boil.
One-phase 220v/50HZ power is available. These controls are as follows:
Power Isolator Switch. Control panel power supply ON/OFF switch, mounted on the panel door.
Power On Indicator. Indicates that the door isolator is in the ON position and the panel is electrically
live.
WARNING
The power on the indicator is derived from on phase. It is possible for that the Power On
Indicator supply phase to be down, leaving the other two phases live. Always isolate the
supply before working on the panel.
1
st
Low Water Indicator.
This lamp will be illuminated and an alarm sounded when the water level in the boiler falls to the 1
st
low water level. The burner will shut down and the alarm will continue to sound until the water level is
restored to a safe working level. The alarm will then cancel, the indicator lamp will extinguish and the
burner will automatically restart.
2
nd
Low Water Alarm/Reset Switch.
Sounds and alarm on switch on, press to reset. If the level of water in the boiler falls below the second
pre-set limit during boiler operation. The 2
nd
Low Water Alarm/Reset Switch will illuminate, the alarm
will sound and the burner will shut down. The water level must be restored before the alarm can be
cancelled by pressing the switch.
High Water Indicator (when fitted).
This lamp will illuminate and alarm sound when the water level reaches a pre-determined high level.
The feed pump will stop. When the water level falls to the normal working level, the indicator lamp will
extinguish and the alarm cancel.
Pump Only/Off/Pump & Burner On.
This rocker switch has three separate functions. In the PUMP ONLY and PUMP & BURNER ON
positions, the power supply is switched through to the control system. It is a mandatory requirement
of the AOTC and gas supply standards that when the control system is first energized, or
re-energized (power restoration), it must go to a fail-safe shutdown position, sound and alarm and
require manual resetting to cancel the alarm. The alarm condition, when activated, is cancelled in
both position by pressing the 2
nd
Low Water Alarm and High Pressure Alarm reset switches.
PUMP ONLY Position. This position should only be selected to fill the boiler. The normal functions of
the level alarm system are overridden to prevent a continuous alarm while the boiler is being filled.
The pump off level will function normally and switch the pump off once the correct water level is
reached.
NOTE
1) The burner mounted Burner ON/OFF/Reset switch should be in the OFF position during
the filling process.
2) The Pump On/Pump off Switch should be in the PUMP ON position.
3) The power restoration alarms will only sound if the burner mounted Burner On/Off/Reset
switch is left in the ON position.
Both alarms will be cancelled when pressing the reset switches irrespective of the water level in the
boiler.
OFF position. In this position the burner, feed pump and control system are off.
PUMP & BURNER ON position. In this position, both burner and pump will run under automatic
control providing that the burner mounted Burner On/Off/Reset Switch is in the ON position, and the
pump On/ Pump Off Switch is in the PUMP ON position.

Fulton Boiler FBS Series
15 FBS 01/05
NOTE
1. When selecting this position from either PUMP ONLY or OFF, the power restoration alarms
will be activated. The alarms can be cancelled by pressing the High Pressure Alarm and
2
nd
Low Water Alarm/Reset switches.
2. The 2
nd
Low Water Alarm can only be cancelled if the boiler water level is above the 2
nd
Low Water Level. If the alarm cannot be cancelled, allow the feed water pump to restore
the water level to the normal working level (approximately mid-way up the sight glass) and
the reset the alarm.
Low Water Safety Relays and Feedwater Pump Relays.
These relays operate in conjunction with probes suspended in the boiler shell to automatically
maintain the water level in the boiler between set limits. If the water should fall to an unsafe level, the
burner is cut out and an alarm is sounded. The probes are located in two, 100mm diameter
standpipes mounted on either side of the boiler centre line towards the front of the boiler. A standard
boiler is fitted with Feedwater pump On/Off, 1
st
Low Water and 2
nd
Low Water probes.
Steam Pressure Controls.
Three steam pressure controls are mounted on the side of the control panel. These are as follows:
a) Control Pressure On/Off Switch. Controls the on/off cycle of the boiler, switching the burner off
when the desired steam pressure is reached and switching it on when steam pressure falls.
b) High Limit Switch. Should the Control Pressure Switch fail, the steam pressure will raise above
the pre-set limit causing the High Limit Switch (set a least 0.5 bar higher than the Control
Pressure Switch) to switch off and lock out the burner. A High Limit Indicator will illuminate and an
alarm will sound.
c) High/Low Pressure Switch. Switches the burner from high to low flame and vice-versa.
Burner Programmer.
Is located in the centre of the control panel. Acts in conjunction with a sensing device to ‘supervise’
the ignition sequence, prove the flame is satisfactory and finally ‘monitor’ the established flame.
Should any fault occur, either during the ignition sequence or during normal running, the programmer
will immediately go to ‘lock-out’ and both main and pilot gas/oil valves will shut to isolate the fuel line
to the burner.
Sequence Manual/Auto Switch (when fitted).
Used to select either manual or automatic sequence step control. In the manual position the burner
will operate under the direct control of the master pressure controller, mounted in the steam
header/distribution pipework. The boiler mounted high pressure and on/off pressure switches are still
functional.
Flame Failure Indicator. Indicates the burner combustion control relay, detects a flame failure
condition.
Hand Indicator (when fitted). This lamp will illuminate when the hand/auto switch mounted inside
the burner control panel is in the hand position, normally used for commissioning only.
Auto Indicator (when fitted). This lamp will illuminate when the hand/auto switch mounted inside the
panel is the auto position.
High Pressure Indicator (when fitted). This lamp is not wired when high steam pressure
alarm/lamp is provided in the boiler control panel.
2. Burner
Fulton boiler FB-S model can mounted with gas burner, oil burner or dual fuel burner on customer’s
requests.
OIL BURNER
The fuel for the oil burner is from No.2 to No.6 oil. The standard
light oil burner for Fulton boiler is No.2 oil. The heavy oil burner
can be used for No.4 to No.6 oil.
1) Air Pressure Switch. Mounted on the burner, this switch is
operated by the pressure of air entering the burner though the
throat of the scroll. Lack of combustion air, or insufficient air
pressure, will stop the switch completing the circuit, preventing
the burner from operating.
2) Air Damper Servomotor. The combustion air control system
including air damper and a servomotor. The servomotor is
mounted on the rear of the air inlet of the burner and directly
coupled to the air damper blade. this system monitors and

Fulton Boiler FBS Series
FBS 01/05 16
controls the combustion air entering the burner on the requirement of the boiler heating during
operating. The standard servomotor of the oil burner is Landis & Staefa STM6 with 5 cam motor.
A fully closed position is provided to prevent air flowing through the appliance when the burner is
not in operation.
3) The Inner Assembly. Consist of flame tube, diffuse, oil nozzle, ignition electrode and so on.
4) Oil Nozzle. The oil nozzles are held in a nozzle block located within the flame tube. The nozzles
are pre-sized by the manufacture according with the heat inputs required and the available
operating pressure. When replace the nozzles, they must be the same capacity as the original.
NOTE
When fitting nozzles to the heavy oil burners the nozzle filters must be removed.
In calculating the correct size of nozzles to be fitted, the following
should be taken into account::
Nozzles are marked for capacity and calibrated at an oil pressure
of 7 bar/100psi. the correction factor to be used to establish the
nozzle sizes is as follow:
Nozzle marking

1.66

Imperial Gallons at 27.6 bar-400 PSI
Nozzle marking

7.16 = Kg/h at 27.6 bar-400 PSI
5) Oil Preheater Tank( for heavy oil burners). The oil preheater
tank is mounted on the heavy oil burner ahead of the fan housing.
Its function is to preheat the oil to correct temperature. The unit is
equipped with three thermostats, ‘low temperature’ ‘operating’ and
‘limit’. A thermometer and hot oil filter are mounted together as
one unit on the top left-hand side of the preheater tank viewed
from the rear of the burner.
GAS BURNER
1) Air Pressure Switch. Each of the gas burners is mounted
a Air Pressure Switch on the burner scroll. Lack of
combustion air, or insufficient air pressure, will stop
the switch completing the circuit, preventing the
burner from operating.
2) Air Control
The Air Control System of the gas burners is similar to
that of the oil burners. The servomotor is mounted on
the rear of the air inlet of the burner and directly
coupled to the air damper blade. This system monitors
and controls the combustion air entering the burner on
the requirement of the boiler heating during operating.
The standard servomotor of the oil burner is Landis &
Staefa STM30 with 3 cam motor. The servomotor has
been adjusted by manufacture before the boiler delivery, so normally customer needn’t to set it again.
3) Gas Train Assembly.
Consist of pilot and main supply line, each line having a manual cock, a governor, solenoid operated
valves and two air pressure switch (high and low). The governors maintain a constant pressure of fuel
entering the burner and are adjustable. The solenoid valves are electronically controlled by the burner
programmer. For specific details, consult the burner manufacture’s instruction Manual.
Three thermostats on the preheater tank

Fulton Boiler FBS Series
17 FBS 01/05
4) Valve Proving System. A valve proving system, as show schematically below, is standard on the
boilers from FB-S3-1.0 to FB-S6-1.25 model.
When the boiler operating sequence is initiated, the burner control box energizes the proving
system, which then carries out the following checks.
a) Valves V1, V2 and V3 are initially closed. The proving system then opens V3 and then closes
it after 2 seconds.
b) V1, V2 and V3 remain closed for 23 seconds while the minimum side of the gas pressure
switch (PS) checks for an increase in pressure. If no crease occurs there is no leakage past
V1 and the sequence continues.
c) V1 is opened for 2 seconds and then closed. V1, V2 and V3 again remain closed for 23
seconds while the maximum side of the gas pressure switch checks for a decrease in
pressure. If no decrease occurs there is no leakage past V2 or V3 and the burner operating
sequence will continue.
5) Flame Monitor. An ultraviolet cell is fitted as standard on all burners. It monitors the status of the
flame, any failure will course the burner shut down.

Fulton Boiler FBS Series
FBS 01/05 18
BURNER OPERATING SEQUENCE
The burner operating sequence begins with a pre-purge period on full air. Fuel is then supplied to the
burner at start rate and ignition initiated. Start flame proving is followed by establishment of the main
flame. Consult the following timing chart.

Fulton Boiler FBS Series
19 FBS 01/05
Section 5
Operating
Boiler starting
Stop! Make sure you have read any followed all previous safety information.
Check with local authorities where approval for start-up is required. In some
localities, final inspection of services may be required.
In general, ensure that the boiler area is in conformance with established boiler
room requirement. Review national and local codes.
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.
1. FILLING THE BOILER
A) Ensure the following valves are OPEN.
i) Main steam valve
ii) Steam pressure gauge isolating valve.
iii) All valves in the water feed line.
iv) Water gauge isolating valves.
v) Air release valve.
B) Ensure the following valves are SHUT.
i) Main blowdown valve
ii) Water gauge blowdown valves.
iii) All valves in the gas/oil train to the burner.
C) Ensure that the Burner On/Off/Reset Switch is set to OFF.
D) Ensure that the Pump On/Off Switch is in the PUMP OFF position, and that the Manual/Off/Auto
Switch is in the Off position.
E) Turn the door isolator to the ON position.
F) Place the Pump On/Off Switch to the PUMP ON position.
G) Place the Pump Only/Off/Burner & Pump Switch to the PUMP ONLY position.
H) The feed pump should start and fill the boiler to the pump off level and then switch off.
NOTE
If the 2
nd
Low Water and High Pressure Alarm/Reset switch illuminate and the alarms sound,
check that the burner mounted Burner On/Off/Reset Switch is in the OFF position, and then
reset both alarms by pressing the switches.
NOTE
It may be necessary to vent the feed water pump by bleeding air from the plug mounted in the
top casting below the pump motor to pump body connection.
2. STARTING THE BURNER FROM COLD
STARTING PROCEDURE
(a) Fill the boiler as described in Section 5.1.
(b) SHUT the main steam valve.
(c) Open all the valves in the gas train/oil supply. It is assured that the fuel supply lines have been
purged prior to attempting to start the boiler/burner.
(d) Turn the Pump Only/Off/Pump & Burner On Switch to the Pump & Burner On position.
(e) Switch the Burner On/Off/Reset Switch to the ON position. The 2
nd
Low Water and High Pressure
Alarm/Reset switches will illuminate and alarms will sound due to the power restoration interlock,
(refer to Section 3.3-Pump Only/Off/Pump & Burner On switch description).
(f) Reset the alarm by pressing both switches. If the 2
nd
Low Water alarm cannot be cancelled, check
the water level in the sight glass.
(g) The burner motor will start and, after going through post purge/ pre purge interlock checks, should
fire after approximately 45 seconds.