FULTON ICW6 - 60 HP User manual

INSTALLATION AND
OPERATION MANUAL
Vertical Tubeless Design
Gas/Oil-Fired Hot Water Boilers
Model ICW
6 - 60 HP
Serial/ National
Board Number
Model
Fulton Order
Sold To
Job Name
Date
ICW-IOM-2012-1001

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ICW-IOM-2012-1001 TABLE OF CONTENTS
0-1
Introduction 1-1
Overview.............................................................................................................. 1-2
Warnings & Cautions............................................................................................ 1-2
Disclaimers and Local Codes ................................................................................ 1-2
Installation 2-1
Placement & Rigging........................................................................................... 2-2
Clearances & Serviceability.................................................................................. 2-4
Environment,Ventilation and Combustion Air Requirements ............................ 2-4
Utilities................................................................................................................. 2-7
THE GAS SUPPLY..........................................................................................................................27
THE OIL SUPPLY ...........................................................................................................................27
Electrical Supply................................................................................................... 2-8
Water Supply........................................................................................................ 2-8
INSTALLWATER PIPING...............................................................................................................28
Water Chemistry Requirements......................................................................... 2-10
PREVENT OXYGEN CONTAMINATION........................................................................................210
ELIMINATE SYSTEM AIR ............................................................................................................211
Piping Specications.......................................................................................... 2-11
Insulation........................................................................................................... 2-12
System Interfaces............................................................................................... 2-12
FILL CONNECTION......................................................................................................................212
PRESSURE GAUGES....................................................................................................................213
Stack and Flue.................................................................................................... 2-13
EXHAUST SIDEWALL VENTING ................................................................................................214
Testing................................................................................................................ 2-14
Operation 3-1
Start-Up Preparation & Installation Review........................................................ 3-2
FillingThe System/Air Removal .......................................................................... 3-2
Start-Up Service................................................................................................... 3-4
Initial Start-Up ..................................................................................................... 3-4
COMBUSTION...............................................................................................................................34
Flame Programmers ............................................................................................ 3-5
Operating Controls............................................................................................... 3-6
WATER RELIEF VALVE...................................................................................................................36
WATER OUTLET VALVE.................................................................................................................36
TEMPERATURE CONTROL ...........................................................................................................36
OPERATING TEMPERATURE AQUASTAT ......................................................................................36
HIGH LIMIT AQUASTAT/HIGH TEMPERATURE LIMIT..................................................................36
AIR SAFETY SWITCH ....................................................................................................................36
PROBE TYPE LOWWATER CUTOFF.............................................................................................36
Circulating Pump Switch...................................................................................... 3-7
CycleTesting......................................................................................................... 3-7
Before Leaving the Installation............................................................................ 3-7
Maintenance 4-1
Daily Maintenance Schedule................................................................................ 4-2
Weekly Maintenance Schedule............................................................................ 4-2
Monthly Maintenance Schedule.......................................................................... 4-2
Recommended Semi-Annual Maintenance Schedule......................................... 4-3
Recommended Annual Maintenance Schedule.................................................. 4-5
Procedure for Primary Air Adjustment/Inspection.............................................. 4-6
Procedure for Secondary Air Adjustment/Inspection.......................................... 4-6
Procedure for Flame Scanner Adjustment........................................................... 4-7
GAS UNIT......................................................................................................................................47
OIL UNIT ......................................................................................................................................47
Procedure for Removing/Cleaning the Burner .................................................... 4-8
Procedure for ControlsVoltageTransformer Inspection ..................................... 4-8
Procedure for Soot Cleaning................................................................................. 4-9
After All Repairs or Maintenance ......................................................................... 4-9
Troubleshooting................................................................................................... 4-9
Warranty & Parts 5-1
Standard Warranty for Fulton Boilers................................................................... 5-3
Parts ..................................................................................................................... 5-4

© The Fulton Companies 2012
TABLE OF CONTENTS ICW-IOM-2012-1001
0-2

Questions? Call [phone], or visit usonline at www.fulton.com 1-1
INTRODUCTION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2012
1-2
INTRODUCTION ICW-IOM-2012-01-04 SECTION 1
Overview
Prior to shipment, the following inspections and tests are
made to ensure the highest standards of manufacturing for
our customers:
§Material inspections
§Manufacturing process inspections
§American Society of Mechanical Engineers (ASME)
welding inspection
§ASME hydrostatic test inspection
§Electrical components inspection
§Operating test
§Final engineering inspection
§Crating inspection
This manual is provided as a guide to the correct operation
and maintenance of your Fulton equipment, and should be
read in its entirety and be made permanently available to the
sta responsible for the operation of the boiler. It should not,
however, be considered as a complete code of practice, nor
should it replace existing codes or standards which may be
applicable. Fulton reserves the right to change any part of
this installation, operation and maintenance manual.
Installation, start-up, and maintenance of this equipment
can be hazardous and requires trained, qualied installers
and service personnel. Trained personnel are responsible
for the installation, operation, and maintenance of this
product, and for the safety assurance of installation,
operation, and maintenance processes. Do not install,
operate, service or repair any component of this
equipment unless you are qualied and fully understand
all requirements and procedures. Trained personnel
refers to those who have completed Fulton Service School
training specic to this product.
When working on this equipment, observe all warnings,
cautions, and notes in literature, on stickers and labels, and
any additional safety precautions that apply. Follow all safety
codes and wear appropriate safety protection. Follow all
jurisdictional codes and consult any jursidictional authorities
prior to installation.
Warnings & Cautions
WARNINGS and CAUTIONS appear in various chapters of this
manual. It is critical that all personnel read and adhere to all
information contained in WARNINGS and CAUTIONS.
§WARNINGS must be observed to prevent serious injury
or death to personnel.
§CAUTIONS must be observed to prevent damage
or destruction of equipment or loss of operating
eectiveness.
All Warnings and Cautions are for reference and guidance
purposes, and do not substitute for required professional
training, conduct, and strict adherence to applicable
jurisdictional/professional codes or regulations.
Disclaimers and Local Codes
Installation of the equipment shall conform to all the
requirements or all national, state and local codes established
by the authorities having jurisdiction or, in the absence
of such requirements, in the US to the National Fuel Gas
Code ANSI Z2231/NFPA 54 latest edition, and the specic
instructions in this manual. Authorities having jurisdiction
should be consulted prior to installation.
When required by local codes, the installation must conform
to the American Society of Mechanical Engineers Safety Code
for Controls and Safety Devices for Automatically Fired Boilers
(ASME CSD-1).

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INSTALLATION
INTRODUCTION 1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
WARRANTY & PARTS 5

© The Fulton Companies 2012
INSTALLATION ICW-IOM-2012-1001 SECTION 2
2-2
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
This boiler is certied for indoor
installation only.
A competent rigger experienced in
handling heavy equipment should
handle rigging your equipment into
position.
The equipment must be installed on a
non-combustible surface.
Ensure all labels on the boiler are
legible. All connections and safety
devices, both mechanical and
electrical, must be kept clean, with
ease of access for inspection, use and
maintenance.
Do not store or use gasoline or other
ammable vapors and liquids or
corrosive materials in the vicinity of
this or any other appliances.
4 CAUTION
Do not allow weight to bear on
equipment components to prevent
damage.
Placement & Rigging
Proper placement of your Fulton Product (see Figures 1 and 2, and Tables 1
and 2) is essential. Attention paid to the following points will save a great deal
of diculty in the future. Correct placement is the rst step to trouble-free
installation, operation and maintenance.
Adhere to the following for equipment placement and rigging:
1. Consult authorities with jurisdiction over any national or local codes
(including but not limited to National Fire Protection Agency (NFPA),
American National Standards Institute (ANSI), Underwriters Laboratories
(UL), SCA, and ASME, which might be applicable to boiler applications
before beginning.
2. Make appropriate determinations for placement, based on the following:
§Check building specications and Table 2 for unit weights.
§Ensure the equipment is to be placed on a non-combustible level base
with adequate clearances from combustible materials. See Clearances &
Serviceability section.
§Locate boiler as close as possible to the place where the heat will be used
in order to keep pipe work costs to a minimum.
§Ensure that there is adequate clearance around the unit to provide
access for operators and maintenance personnel to all parts of the
equipment. Ensure also that clearance provides for component removal for
maintenance. See Clearances & Serviceability section. The equipment
should be placed in a suitable boiler house or well ventilated separate
room through which personnel do not normally pass. The layout should
eliminate trac in potentially hazardous areas. For instance, the service
engineer or the operator should not have to pass exposed, hot pipe work
to make adjustments to the boiler controls.
§Ensure the equipment is to be placed in such a way that the electrical
components are protected from exposure to water or excessive humidity.
§Ensure the boiler is located a safe distance from the fuel oil tank (if
applicable).
3. Determine rigging procedure, based on the following:
§Units are shipped and crated for forklift transport. Once uncrated, all units
can be transported with a forklift and/or lifting lugs at the top of the boiler.
All skidded units can be moved with forklifts.
§If means of lifting are not available, place rollers beneath the frame of the
equipment for guidance to the position of where it is to be installed.
§Under no circumstances allow weight to bear on the jacket, control panel,
burner, fuel train or fan housing of any Fulton boiler.

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SECTION 2 ICW-IOM-2012-1001 INSTALLATION
2-3
TABLE 1 DIMENSIONS REFER TO FIGURE 1
Model ICW 6 10 15 20 30 50 60
Unit Size BHP 6 10 15 20 30 50 60
A. Boiler Height
IN
MM
57.5
1461
63.5
1613
69.5
1765
72.5
1842
82.5
2096
87.5
2223
93.5
2375
(B) Boiler Height with Trim* and Fuel Train Assembly
IN
MM
75
1905
80.5
2045
86.5
2197
92.5
2350
102
2591
106.5
2705
120
3048
(C) Overall Depth Stack to Burner Fan Housing
IN
MM
44
1118
46
1168
47
1194
60
1524
67
1702
78
1981
78
1981
(D) Boiler Diameter
IN
MM
26
660
28
710
30
760
39
990
46
1170
55
1400
55
1400
(E) Flue Outlet Diameter
IN
MM
6
152
6
152
8
203
10
254
12
305
12
305
12
305
(F) To Center of Flue Outlet
IN
MM
52
1320
58
1473
63
1600
66
1675
73.5
1867
79
2007
85
2159
(G) Return Water Inlet Height
IN
MM
15.5
394
16
406
16.25
413
17.25
438
17.5
445
18.75
476
18.75
476
(H) Overall Width
IN
MM
31
787
33
838
35
889
42.5
1080
50.5
1283
58
1473
58
1473
(I) Gas Train Extension (CSD-1)
IN
MM
22.5
572
21.5
546
20.5
521
25
635
27
686
22.5
572
34
867
(J) Clearance Required for Trim & Burner Removal*
IN
MM
82
2082
86
2184
92
2337
96
2438
106
2692
114
2896
124
3150
*This dimension is 6 inches (152.4 mm) less for oil red units.
F
D
C
K
A
J
B
G
O
M
EH
L
N
I
Side View Front View
Top View
FIGURE 1 MODEL ICW DIMENSIONS/SPECIFICATIONS REFER TO TABLES 1 AND 2

© The Fulton Companies 2012
INSTALLATION ICW-IOM-2012-1001 SECTION 2
2-4
NOTE:´When calculating ventilation requirements, heat losses from the Fulton
equipment (and other equipment) should be considered.
Clearances & Serviceability
Adhere to the following for equipment clearances and serviceability:
1. Ensure appropriate front, back, sides and top clearances are met. This
will allow access around the equipment to facilitate maintenance and a
safe work environment, and ensure technicians will commission the unit.
Technicians will not commence commissioning if hazardous conditions
exist.
2. Place boiler with clearances to unprotected combustible materials,
including plaster or combustible supports, not less than the following:
§Heater Front: 36 in. (914 mm)
§Heater Sides and Rear: 18 in. (457 mm)
§Heater top: 24 in. (610 mm)
§Allow for additional minimum clearances for personnel access and burner
removal, as necessary.
§Verify that all clearances are acceptable with the local ordinances.
Environment, Ventilation and Combustion Air
Requirements
It is critical to provide free access of air to the boiler. To burn fuel properly, it
requires one square inch opening for every 3,000 BTU input of fuel (6.4 cm2 for
every 756 kCal).
Adhere to the following to meet ventilation and combustion air requirements:
1. Install two fresh air openings, one at a low level, 24”(610 mm) from the
oor, and one at a higher level on the equipment room wall. This will
provide a ow of air to exhaust the hot air from the equipment room.
2. Ensure the equipment room air supply openings are kept clear at all times.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
Crystalline silica may be present in
components of this equipment. Exposure
to crystalline silica may pose signicant
health hazards, including but not limited
to eye and respiratory system damage.
Per the Centers for Disease Control and
Prevention (CDC) and Occupational
Safety and Health Administration
(OSHA), appropriate Personal Protective
Equipment must be worn to minimize
exposure to hazardous substances. Refer
to most current guidelines oered by the
CDC and OSHA for more information,
including Personal Protective Equipment
recommendations.
Failure to provide required and safe
access to the equipment could impede
commissioning and maintenance.
Service technicians are instructed not to
commence commissioning if hazardous
conditions exist.
Failure to provide proper minimum
clearances between equipment and
combustible materials may result in re.
The installation of an exhaust fan in the
boiler room is not recommended. An
exhaust fan or similar equipment can
create a downdraft in the stack or restrict
the burner’s air supply and result in poor
combustion. It is essential only fresh
air be allowed to enter the combustion
air system. Foreign substances such as
combustible volatiles and lint may create
hazardous conditions.

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SECTION 2 ICW-IOM-2012-1001 INSTALLATION
2-5
TABLE 2  SPECIFICATIONS REFER TO FIGURE 1
Model ICW 6 10 15 20 30 50 60
Boiler Connecons
K. Safety Valve Outlet
IN
MM
0.75
19
0.75
19
1.5
38
1.5
38
1.5
38
1.5
38
1.5
38
L. Safety Valve Inlet
IN
MM
0.75
19
0.75
19
0.75
19
1
25
1
25
1.25
32
1.25
32
M. Water Inlet Size
IN
MM
1.5
38
2
51
2.5
64
2.5
64
3
76
4
102
4
102
N. Hot Water Outlet Size
IN
MM
1.5
38
2
51
2.5
65
2.5
65
3
76
4
102
4
102
O. Boiler Drain Size
IN
MM
1
25
1
25
1
25
1.25
32
1.25
32
1.5
38
1.5
38
Approx. Shipping Weights
LB
KG
1700
771
2000
910
2380
1080
3400
1542
4780
2168
6526
2960
7280
3302
Rangs* (sea level to 3000 ) Output
1000 BTU/HR
1000 KCAL/HR
201
51
335
84
502
127
678
171
1017
256
1645
427
2034
513
Approximate Fuel Consumpon at Rated Capacity+
Light Oil
GPH
LPH
1.8
6.8
3
11.4
4.5
17
6
22.7
9
34
15
57
17.9
67.8
Propane Gas
FT3/HR
M3/HR
100
2.8
168
4.8
251
7.1
335
9.5
502
14.2
837
23.7
1004
28.4
Natural Gas
FT3/HR
M3/HR
251
7.1
419
11.9
629
17.8
838
23.7
1256
35.4
2093
59.3
2511
71.1
Natural Gas Boiler Connecon Size (Std CSD-1)
IN
MM
1
25
1
25
1
25
1.25
32
1.5
38
1.5**
38
2
51
Oil Inlet Connecon Size
IN
MM
.25
6
.25
6
.25
6
.25
6
.25
6
.25
6
.25
6
Burner Motor HP
3450 RPM/60 CY
2850 RPN/50 CY 1/3 1/3 1/3
1/3 gas
3/4 oil 3/4
1.5 gas
2 oil
1.5 gas
2 oil
Electric Power Requirements - Burner Only (in amps)
120V 60 CY 1 Phase 7.2 7.2 7.2 7.2 gas
13.8 oil
13.8 ____ ____
230V 50/60 CY 1 Phase 3.6 3.6 3.6 3.6 gas
6.9 oil
6.9 10 gas
12 oil
10 gas
12 oil
208V 50/60 CY 3 Phase 1.9 1.9 1.9 1.9 gas
3.5 oil
3.5 6.6 gas
7.5 oil
6.6 gas
7.5 oil
230V 50/60 CY 3 Phase 1.6 1.6 1.6 1.6 gas
3.2 oil
3.2 6.0 gas
6.8 oil
6.0 gas
6.8 oil
460V 50/60 CY 3 Phase .8 .8 .8 .8 gas
1.6 oil
1.6 3 gas
3.4 oil
3 gas
3.4 oil
Water Content
U.S. GAL
LITERS
21
80
35
132
54
204
104
394
208
787
291
1101
315
1192
+ Consumpon based on light oil 140,000 BTU/GAL, Natural Gas 1010 BTU/3, Propane 2530 BTU/3.
** CSA gas train size is 2 inches (50.8 mm) Natural gas pressure required/main inlet is 7-11” W.C. LP Gas Pressure required main inlet is 14” W.C. Natural Gas Pressure required/last elbow is
3/5” W.C. and back pressure. LP Gas pressure required/last elbow is 11” W.C. No. 2 Oil Pressure required/oil pump is 230 PSI.
Notes: Model sizes up to and including ICW30 have threaded inlet and outlet as shown on schemac. All larger sizes have flanged inlet and outlet. Models ICW50 and ICW60 are provided
with an extra plugged safety valve for extra relief capacity. For custom fuel trains, consult Factory for sizing and connecons.

© The Fulton Companies 2012
INSTALLATION ICW-IOM-2012-1001 SECTION 2
2-6
3. See Table 3 for minimum make up air openings required
for each model.
TABLE 3 MINIMUM MAKE UP AIR OPENING REQUIREMENTS
Model Fresh Air Opening FT2 (M2)
ICW 6 1 (.09)
ICW 10 1 (.09)
ICW 15 1.5 (.14)
ICW 20 4 (.37)
ICW 30 4 (.37)
ICW 50 5 (.46)
ICW 60 7.5 (.69)
Transformer Scroll
Gaskets
Burner Motor
Control Box
High Density
Insulation
Outside Jacket
Handhole
Boiler Runners
Flue Outlet
Lifting Hook(s)
Flue Blanket
Flue Rope Gasket
Flue Plate Cover
Top Plate Assembly
Gas Train Assembly
Secondary Air Damper
Burner Plate
Assembly
Stainless Steel Ring (oil only)
Bottom Refractory
Top Refractory
Castable
Refractory
Insulation
Water Return
4. If positive forced ventilation is adopted, ensure that
there will be no appreciable pressure variation in the
equipment room.
5. Avoid ventilation which creates a negative pressure
in the building as it will seriously aect combustion
and proper operation of the burner. Please note that
exhaust fans or similar equipment can create a down
draft in the chimney or starve the burner’s air supply.
Either case may result in poor combustion or nuisance
failures. A properly designed make-up air system in the
equipment room will preclude these possibilities and is
required to maintain proper combustion.
FIGURE 2 COMPONENT VIEW OF THE ICW UNIT

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SECTION 2 ICW-IOM-2012-1001 INSTALLATION
2-7
6. Eliminate potential for high risk situations for particulate matter to
be in the combustion air supply (e.g., as a result of construction and
maintenance activities).
Utilities
¡The Gas Supply
Adhere to the following for gas supply installation:
1. Install gas piping in accordance with all applicable codes.
2. Ensure pipe and ttings used are new and free of dirt or other deposits.
3. Ensure piping is of the proper size for adequate gas supply to the gas head
assembly. Consult your gas company for specic recommendations.
4. When making gas piping joints, use a sealing compound resistant to the
action of liqueed petroleum gases. Do not use Teon tape on gas line
heads.
5. Ensure no piping stresses are transmitted to the equipment. The
equipment shall not be used as a pipe anchor.
6. Ensure all vent connections on diaphragms, gas valves, pressure regulators,
and pressure switches (gas-red units) are vented per local code.
7. On gas-red units with NFPA 85 valve trains, ensure the vent valve is piped
to atmosphere per local code.
8. During any pressure testing of the system at pressures in excess of 1/2 psig
(14 inch W.C.), isolate the with the manual shuto valve (located at the end
of the supplied gas train) from the gas supply piping system.
9. Ensure the supply pressure is regulated by a non-stacking, tight, shut-o
regulator.
10. Arrange gas piping so that it does not interfere with any cover or burner,
inhibit service or maintenance, or prevent access between unit and walls
or another unit.
11. After gas piping is completed and before wiring installation is started,
carefully check all piping connections, (factory and eld), for gas leaks. Use
an appropriate leak test solution.
¡The Oil Supply
Adhere to the following for installation:
1. Fuel pipes must be of approved materials and of a diameter suitable for the
quantity of oil being delivered to the burner. Vacuum must not exceed 10
in. (254 mm) of mercury at the pump inlet. Maximum inlet pressure to oil
pump is 3 PSIG.
2. Make fuel connection in accordance with the details on the enclosed fuel
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
A qualied installer, service agency or the
gas supplier must perform installation and
service on the fuel delivery system.
Do not use matches, candles, ame or
other sources of ignition to check for gas
leaks.
What to do if you smell gas:
Do not try to light the appliance.
Do not touch any electrical switch.
Do not use any phone in the building.
Leave building and contact gas supplier
from neighbor’s phone. If you cannot
reach gas supplier, phone the re
department.
When making gas piping joints, maintain
proper ventilation to reduce breathing
hazards.
An exhaust fan may draw products of
combustion into the work environment
creating a possible hazard to personnel.
4 CAUTION
It is essential that only fresh air be allowed
to enter the combustion air system. Foreign
substances, such as combustible volatiles
and lint in the combustion system can create
hazardous conditions. If foreign substances
can enter the air stream, the combustion air
inlet must be piped to an outside location.
Failure to do so will void the warranty.
To avoid failures due to poor combustion,
ensure make-up air system is properly
designed.

© The Fulton Companies 2012
INSTALLATION ICW-IOM-2012-1001 SECTION 2
2-8
pump cut sheet.
3. Ensure fuel oil piping is in accordance with local/national requirements.
4. Meet the maximum pressure allowed at the fuel oil pump inlet per the
National Fire Protection Association (NFPA).
5. Oil burners are of a two-pass design system, requiring a return line and a
supply line. The oil pump is factory set per Test Fire Sheet. Do not alter the
setting without consulting the factory.
6. A stop valve, a check valve, and an oil lter must be installed on the oil
supply line.
7. Ensure there are no loose ttings. Loose ttings in the fuel oil line will
permit air to enter the fuel line and cause improper ring.
Electrical Supply
Adhere to the following for electrical supply installation:
1. Locate electrical schematic diagram, a copy of which is inside of the panel
box.
2. Ensure the information on the electrical drawing corresponds to your
voltage and frequency. Check the supply voltage and make sure that there
is no over- or under-voltage exceeding 10% of the nominal value.
3. Install a separate fuse switch for the contactor and a separate fuse switch
for the circulating pump. If pump motor is 3/4 HP or larger, install an
across-the-line starting switch ahead of the circulating pump motor.
4. Install wiring and ground in equipment in accordance with authority
having jurisdiction or in absence of such requirements the National
Electrical Code, ANSI/NFPA.
5. Provide a fused disconnect sized for the unit. Size fuses according to motor
name plates and local electrical codes.
6. Connect power to the terminal strip as supplied on the inside of the panel
box.
Water Supply
¡Install Water Piping
All water supplies contain some solids, dissolved gases or dissolved minerals.
These may cause corrosion, deposition and/or fouling of equipment. To prevent
these contaminants from impacting boiler performance, valve operation and
general pipe longevity, each location must be analyzed and treated accordingly.
Adhere to the following for water piping installation:
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
4 CAUTION
Loose ttings in the fuel oil line will permit
air to enter the fuel line and cause improper
ring.

Questions? Call [phone], or visit usonline at www.fulton.com
SECTION 2 ICW-IOM-2012-1001 INSTALLATION
2-9
1. Isolation valves and unions are recommended on both water connections
for ease of service.
2. Install piping so that the boiler is not supporting any additional piping.
3. Install manual purging valves in all loops and zones. Install a pressure-
reducing (automatic ll) valve in the cold water ll line to the boiler system.
Check that the proposed operation of zone valves, zone circulator(s) and
diverting valves will not isolate air separator(s) and/ or expansion tank(s)
from the boiler. Clearance from hot water pipes to combustibles must be at
least 6 inches (152 mm).
4. Pipe the water supply line to the lower opening on the back of the boiler.
Water stop valve should be in line between the boiler and the rst piece
of equipment. Hot water outlet should be piped to process/equipment
requiring hot water. Water makeup supply should be installed. Hot water
inlet should be piped to the make-up water supply.
5. Pipe the water safety valve from the outlet of the valve to a safe blow-o
point.
NOTE:´Do not alter water temperature/pressure gauge assembly in any way.
6. Drain valve is connected to the lowest opening at bottom rear of boiler.
Carry piping from the outlet of the valve to safe drain point. Provision
should be made for easy access to drain valve of boiler.
NOTE:´The water connection on the top of the boiler is the outlet connection. The
water connection on the rear of the boiler is the inlet connection.
7. Install ltration to remove particulates if appropriate.
8. Install bypass chemical feeder for corrosion inhibitor maintenance if
appropriate.
9. Install corrosion coupon holder to assess corrosion inhibitor performance if
appropriate.
NOTE:´The boiler is provided with a drain valve connection and a drain valve.
10. Heating system:
»An automatic pressure activated water make up valve with back
ow preventer. It must be set to maintain required Net Positive
Suction Head (NPSH) for re-circulating pumps, a positive system
pressure at the highest point of at least 5-10 PSIG, and make up
water valve should be designed to add water to the system at the
outlet of the boiler and should not be fed directly into the boiler.
»Air removal equipment, including an air separator and automatic
breather valves, along with a functioning expansion tank . Each
must be designed to system specications.
11. When used in conjunction with a refrigeration system, install the boiler
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.

© The Fulton Companies 2012
INSTALLATION ICW-IOM-2012-1001 SECTION 2
2-10
so that the chilled medium is piped in parallel with the boiler with
appropriate valves to prevent the chilled medium from entering
the boiler. If the boilers are connected to heating coils (located in air
handling units where they may be exposed to refrigerated air circulation)
such boiler piping systems must be equipped with ow control valves or
other automatic means to prevent gravity circulation of the boiler water
during the cooling cycle.
Water Chemistry Requirements
System water chemistry requirements are as follows:
§pH: Range of 8.5 - 10.5
§Oxygen: Less than 250 ppb (operating condition)
§Total Iron/Copper: Less than 5 ppm
§Corrosion Inhibitor: Capable of maintaining iron corrosion rates <2
mpy. Due to changing environmental restrictions a non-heavy metal
ALL ORGANIC inhibitor is recommended which is designed for multi
metal systems including ferrous metals and yellow metals such as
copper and brass.
§Chloride: Less than 250 ppm
Adhere to the following:
1. Refer to your water conditioning or chemical treatment supplier for
analysis and recommendations for proper system conditions.
2. Follow a program with appropriate monitoring and maintenance of
system water conditions as provided by your water conditioning or
chemical treatment supplier.
3. Operate the boiler in a closed-loop system using water or water/glycol
(not requiring a make-up water supply). A large amount of improperly
treated make-up water can cause premature failure of the heat
exchanger resulting from scale build up. Scale build up will reduce the
eciency and useful life of the boiler and is not covered under warranty.
¡Prevent Oxygen Contamination
There are several ways to prevent boiler water oxygen contamination:
§Minimize system leaks to minimize make up water requirement
§Do not use open tanks or ttings
§Do not use oxygen permeable materials anywhere in the water
system
§Repair leaks in the system quickly
§Eliminate ttings wherever possible
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
4 CAUTION
A large amount of improperly treated make-
up water can cause premature failure of the
heat exchanger resulting from scale build
up. Scale build up will reduce the eciency
and useful life of the boiler and is not
covered under warranty.

Questions? Call [phone], or visit usonline at www.fulton.com
SECTION 2 ICW-IOM-2012-1001 INSTALLATION
2-11
§Use air elimination devices in system piping
¡Eliminate System Air
NOTE:´There are no built-in boiler air eliminating features.
Adhere to the following for air elimination:
1. The installation of an air separator and air eliminator (air vent) is required.
2. To prevent scale corrosion in boiler and associated piping, make up water
must be kept to a minimum. This is best achieved by ensuring immediate
repair of all leaks and that system pressure is maintained.
3. If a sealed diaphragm-type expansion tank is used, install an air eliminator
in the hot water piping at the air separator.
4. If an air cushion type expansion tank is used, pipe tank directly into boiler
supply.
5. On multi-zoned systems (or a system with both space and domestic water
heating), air elimination must be provided either in the common piping or
on every loop.
6. When the boiler is installed at a higher level than baseboard radiation (if
used), air elimination must be provided directly above the unit.
Piping Specifications
For piping, the basic considerations are: the design temperature, the pressure
retained by the pipe, the uid in the pipe, the load resulting from thermal
expansion or contraction, impact or shock loads imparted such as water hammer,
external loads, wind loads and vibration from equipment.
Adhere to the following for piping installation:
1. Ensure the arrangement of the piping and its appurtenances takes into
consideration the location of other structures and equipment adjacent to
the piping, which may result in freezing interference and/or damage as a
result of expansion, contraction, vibration, or other movements.
2. Consider the appropriate location and orientation of valves necessary
for safe operation and isolation of the piping. Valves are used in piping
systems to stop and start the ow of uids, to regulate ow, to prevent the
back ow, and to relieve excessive pressure build up in the piping.
3. Ensure all piping and piping components are suitable for the design
temperatures, pressure and uid used in the system.
4. Ensure all pipework is constructed from seamless mild steel pipe, Schedule
40 or Schedule 80 as required by code and/or application; or copper if
system parameters allow.
5. During construction of the installation, ensure that no dirt, water, or
residue from welding is left in the system.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct, and strict
adherence to applicable jurisdictional/
professional codes and regulations.
The vent line connection on the gas
pressure regulator must be piped to
outdoor air by the installer in accordance
with National Fuel Gas Code, ANSI Z223-
1-1991 or latest addenda. In Canada, gas
installations must be in accordance with
the current CAN/CGA B149.1 and 2 and/or
local codes.
4 CAUTION
Some soap used for leak testing is
corrosive to certain types of metals. Use
an appropriate leak test solution. Clean all
piping thoroughly after completing the leak
check.

© The Fulton Companies 2012
INSTALLATION ICW-IOM-2012-1001 SECTION 2
2-12
6. Provide expansion joints or properly designed and sited loops to
accommodate thermal expansion. Thermal expansion should be calculated
using the maximum possible utilization uid temperature, regardless of
whether the pipe considered is in the feed or return circuit. Steel pipe will
expand approximately 1“ per 100’over a 100° F temperature rise (1 mm
per meter over 100 C rise).
7. Provide supports and anchors for all pipes where necessary to prevent
undue stresses from being placed on items of equipment, including
pumps, valves, and the boiler. Supports and anchors which will not
interfere with thermal expansion should be chosen.
8. Screwed joints may be used for connections 2.5 inches (63.5 mm) and
smaller. For larger diameters, all pipe joints should be either welded or
anged construction. Flanges should be 150# or 300# raised face anges.
9. Cut screw threads carefully and accurately. If possible, new tools should be
used. It is recommended that GR5 or higher tensile steel bolts be used for
all anged joints.
10. Use gaskets to make all anged connections. Gasketing material must be
suitable for use with the pressure, temperatures and uids in the system.
Ensure that all bolts are tightened evenly and to the torque recommended
values provided by the gasket manufacturer.
11. Install high point bleeds at all high points in the system piping. 1/2”x 12”
nipples welded in the top of the piping with ball valves and plugs attached
are to be used.
12. Install all pipes with a pitch to facilitate draining and venting.
Insulation
After the appropriate system tests have been satisfactorily completed (see
Testing section of this manual), all hot pipework and vessels must be adequately
insulated with material suited to the temperature and application to prevent
both heat loss and personnel injury. For inspection and maintenance purposes,
leave pumps, anges, valves and ttings uninsulated but suitably shielded for
safety. Removable insulation may also be used over these components.
System Interfaces
Proper selection and installation of the components in the system will ensure
proper and safe operation of the boiler. Consult Fulton representative or contact
Fulton at [phone].
¡Fill Connection
The system is usually lled from the lowest point, with the aid of a pump. On skid-
mounted units, a ll connection is provided in the inlet piping to the pump.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Hot pipework and vessels must be
adequately insulated with material
suited to the temperature and
application to prevent both heat loss
and personnel injury.

Questions? Call [phone], or visit usonline at www.fulton.com
SECTION 2 ICW-IOM-2012-1001 INSTALLATION
2-13
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Assure all electrical connections are
powered down prior to attempting
replacement or service of electrical
components or connections of the
equipment.
Cements for plastic pipe should
be kept away from all sources of
ignition. Proper ventilation should
be maintained to reduce the hazard
and to minimize breathing of cement
vapors.
No shuto of any kind may be
placed between the safety relief
valve and the equipment, or in the
discharge pipe between such valve
and the atmosphere. Doing so may
cause accidental explosion from
overpressure.
Discharge from safety relief valve
must be congured so that there
is no danger of scalding personnel
or causing equipment damage.
Provisions must be made to properly
drain safety relief valve discharge
piping.
For reasons of safety, the hot exhaust
gas duct and chimney must be
insulated or shielded within the
locality of the heater in compliance
with local codes and regulations.
4 CAUTION
The stack arrangement and draft
conditions should be in accordance
with the information in this manual for
proper performance of the equipment.
¡Pressure Gauges
The range in which readings are expected to fall should comprise mid-scale
on the pressure gauge chosen. Pressure gauges must be able to withstand
overpressure equal to the rating of the safety relief valves, normally 100 psig.
NOTE:´The Water temperature pressure gauge should not be altered in any way.
Stack and Flue
An appropriately sized stack should be connected to the ue gas outlet at the
boiler. The proper ue size and draft control is most important for proper burner
operation. See Table 4.
TABLE 4  MINIMUM FLUE SIZES
Model Minimum Flue Size
inches (mm)
6 6 (152)
10 6 (152)
15 8 (203)
20 10 (254)
30 12 (305)
50 12 (305)
60 12 (305)
80 14 (356)
The ue must be as large or larger than the outlet on the vessel. Avoid ue
piping and elbows by placing the equipment as close as possible to the chimney.
Adhere to the following for stack and ue installation (see Figure 3):
1. Ensure the stack rises continuously to the connection at the chimney and
contains no more than two bends at 45 degree angles or less. If required,
as a result of space limitations, one 90 degree elbow (or tee) can be tted
at the back of the vessel.
2. Ensure 2 feet (0.6 m) of straight, horizontal ue before any change in
direction, tting or draft regulator. This is to prevent potential pilot or
main ame failures due to back pressure build up during ignition. Any
alternative stack arrangement must supply negative 0.02 to 0.04”wc.
3. Ensure the run in the total distance of stack ducting, as measured in a
straight line from the outlet of the boiler to the outlet of the stack, does
not exceed 25% of the rise. With the exception of the duct run previously
described, horizontal sections of ducting must be avoided and should not
exceed 4 feet (1.2 m) total. See Figure 3.
4. Ensure the stack, chimney, and any components associated with the stack,
such as heat reclaimers or assist fans, are constructed from material that is
rated for a 1000 F (538 C) operating temperature.

© The Fulton Companies 2012
INSTALLATION ICW-IOM-2012-1001 SECTION 2
2-14
5. Ensure the stack and chimney material complies with all applicable codes.
6. Make adequate provisions for the support of the weight of the chimney
and stack to avoid having a load imparted to the outlet connection of the
equipment.
7. Ensure the draft, when ring, is negative and constant. A reading of -0.02
to -0.04”wc (-0.508 to -1.016 mm) when the unit and stack are cold usually
indicates sucient draft. When the unit is running and the stack is hot, the
draft should read -0.04 to -0.08“wc (-1.016 to -1.524 mm) negative.
8. The installation of a draft regulator by the client/contractor is
recommended at all installations. This will help to maintain the required
draft. The placement of the draft regulator should be as shown in Figure 3.
Insulate the section of the chimney duct within the building.
9. Concentration levels of only a few ppm of chlorine containing compounds
in combustion air can produce serious corrosion of the ue over long
periods of time. High chlorine containing compounds such as carbon
tetrachloride or perchloroethylene would be prime suspects.
¡Exhaust Side Wall Venting
Boilers for which sidewall venting (Figure 4) may be utilized are propane, natural
gas, or combination propane and natural gas sizes 10 to 30 HP.
Adhere to the following for installations requiring sidewall venting:
10. Flue vent piping must be pitched upward at ¼ in (6.35 mm) per one foot
(3.048 m) of length.
11. An UL-approved Fulton factory-supplied draft fan must be installed to
provide sucient draft (-0.02 to -0.04”wc) to safely vent products of
combustion.
12. The draft fan should be located as close to the ue outlet as possible.
13. Draft regulation sucient to lower the draft to between -0.02 to -0.04“ wc
may be required. The draft regulator must be between the boiler and the
fan.
14. The draft fan shall have an air ow proving switch wired in series with the
boiler air safety switch.
15. The sidewall vent total length from boiler exhaust to termination shall not
exceed 35 feet (10.6 m) with 4 elbows maximum.
Testing
Upon completion of the installation, perform the following testing:
1. A pneumatic test of water piping not exceeding 15 psig.
2. Leak tests at all welds and joints to ensure that the system is free from
leaks.
! WARNING
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional/professional codes and
regulations.
Non-Fulton product information is for
reference purposes only. No Fulton
document may substitute for full
review of documentation available
from the component manufacturer.
4 CAUTION
Boilers damaged due to adverse water
conditions are not covered by warranty.
The weight of all piping must be
properly supported. Failure to support
piping may result in equipment
damage and/or system leakage.
Piping must take into consideration
potential for freezing interference and/
or damage as a result of expansion,
contraction, vibration, or other
movements.
Dirt, water, and/or other debris in the
piping system after welding may result
in equipment failure.
To maintain a reasonable
temperature in the equipment area
and ensure safety to personnel, the
section of the chimney duct within
the building should be insulated.