FULTON J Series - User Manual

Other manuals for FULTON J Series

Installation, Operation And Maintenance Manual76 pages

Questions and Answers

M
mwrightSep 23, 2025
What should I do if the FULTON Boiler pump runs but doesn't pump water?
- M
  Michael WagnerSep 23, 2025
  If the FULTON Boiler pump runs but does not put water in the boiler, allow the system to cool down, check steam traps, and ensure return lines are not insulated. Check the return tank temperature; if it's above 82[O]C, vapor locking of the pump will occur. Inspect check valves, cleaning and replacing as needed. Replace the pump with a multi-stage centrifugal pump able to cope with 121[O]C. Check the feed water line is not blocked, clean as required.
E
Eric WaltersSep 22, 2025
What to do if the pump will not cutoff on my FULTON Boiler?
- C
  Christine CarterSep 22, 2025
  If the FULTON Boiler pump will not cutoff, clean or replace dirty probes as required. Check the relay is secure on its base, if so replace the relay. Check the earth connection for tightness and clean.
J
James ShortSep 18, 2025
What causes a FULTON Boiler to push water with steam?
- U
  ugriffinSep 18, 2025
  If the FULTON Boiler is pushing water with steam, check the traps, cleaning or replacing them as required. If there is too much water treatment, dump the return tank and flush the system. Test the water treatment.
J
jacob71Sep 18, 2025
Why is my FULTON Boiler rumbling?
- L
  Luis GonzalezSep 18, 2025
  If the FULTON Boiler rumbles, check that the draft is neutral and consider installing a barometric damper if the draft is too strong. Adjust the main air if there is too much. Check the tank and lines for water or leaks if there is air or water in the oil.
R
Rebecca MillerSep 16, 2025
What causes a FULTON Boiler to start surging?
- E
  Eric RuizSep 16, 2025
  If the FULTON Boiler is surging, check the steam traps, and clean or replace as required. Contact a water treatment company and consult the factory regarding scale buildup or lime deposits. If there is too much water treatment, dump the return tank and flush the system, then test the water treatment. Check the total equipment load against the boiler output and decrease the amount of equipment being used if there is too much of a load.
K
Katie MillerSep 13, 2025
What causes flooding in a FULTON J Series?
- R
  Randall LeeSep 14, 2025
  Flooding in a FULTON Boiler can occur if the pump does not shut off, which may be due to dirty probes; clean or replace them as necessary. A failed relay can also cause flooding; ensure the relay is secure on its base, and if so, replace the water level relay. An issue with the earth connection can also lead to flooding; clean and tighten as required. Additionally, a vacuum created with the boiler off can pull water from the system piping; to prevent this, add a check valve on the steam gauge assembly piping that closes under pressure and opens under vacuum.
L
Larry MurraySep 12, 2025
Why won't the water pump on my FULTON J Series come on sometimes?
- A
  Austin EllisSep 12, 2025
  If the water pump on your FULTON Boiler won't come on at times, it could be due to scale on the probes, so check and clean the probes, replacing them if necessary. A faulty pump contactor could also be the cause, so check the contactor has power and is pulling in, and replace it if necessary. A faulty pump motor could also be the issue, so check the pump has power; if it does but isn't running, replace it. Finally, a faulty level control relay could be the cause, so check the relay has power and is secure on its base, and replace it if faulty.
N
Natalie ClarkAug 27, 2025
How can I fix a FULTON J Series that won't maintain pressure?
- C
  colsonAug 27, 2025
  If your FULTON Boiler won't maintain pressure, consider the following: First, check the gas supply for adequate pressure and flow. Next, inspect the flue for carbon build-up or blockages and clean it if necessary. Test the pressure control by disconnecting power and wires, then using an OHM meter to check switch operation as you lower and raise the set point; replace the controller if it operates improperly. Also, inspect the boiler for scale build-up and clean the pressure vessel. Check the refractory bricks for blockages or damage, cleaning or replacing them as needed. Examine steam traps for blow-through, cleaning or replacing them as required. Finally, consider whether the boiler may be undersized for the current load.
J
James WilliamsAug 30, 2025
Why does my FULTON J Series Boiler experience flame failure during normal run?
- K
  Karen MeyersAug 30, 2025
  If your FULTON Boiler experiences flame failure during normal run, possible causes include issues with the power supply, so check the fuse or circuit and reset or replace as necessary. Problems with the gas supply, so check gas pressure coming into the gas train, if low contact the gas supplier and check the setting on the gas valve regulator, adjust as required. The UV detector may be incorrectly located or dirty, so check the detector is located correctly and clean it. A faulty air switch could also be the cause, so check for a faulty air switch. Finally, bad combustion can lead to flame failure, so check combustion readings.
R
Russell CollinsAug 31, 2025
What causes burner cut-off in a FULTON Boiler?
- Q
  qwatsonAug 31, 2025
  Burner cut-off in a FULTON Boiler can be caused by several factors. Check the filters in the gas valve block and clean them if required. Adjust the pilot to a larger size by adjusting the pilot gas pressure regulator if you have a weak pilot. Test the level controls and adjust or replace them as required if there is a faulty level control. Clean or replace the UV detector if it is dirty or defective.

Summary

Introduction

Technical Data

Specifications and performance data for various boiler models.

Installation

General

Siting

Ventilation

Flue Outlet

Water Supply

Steam Safety Valves

Information on factory-set safety valves and discharge piping.

Oil Supply

Positioning of oil storage, feed/return lines, filters, and valves.

Commissioning the Boiler

Procedures for boiler commissioning by a service engineer.

Cleaning Steam Lines and Pressure Vessels

Safety

General Safety Instructions

Importance of observing operation/maintenance instructions for safety.

Maintenance and Repairs

Warning against performing unknown maintenance; consult service engineer.

Electrical Safety

Warning to understand circuits before connecting/disconnecting electrical components.

Defective Boiler Operation

Do not operate a defective boiler; ensure all maintenance is done.

Hydraulic Test Risk

Risk of brittle fracture during hydraulic testing below 5°C.

Water Quality Importance

Low Feed Water Temperature

Qualified Personnel Only

Only qualified persons should operate/maintain the boiler.

Fuel Modification

Unauthorized Modifications

Lifting Equipment Safety

Operating Limits

Do not operate beyond design limits; avoid unapproved upgrades.

Hot Surfaces Danger

Steam boilers have hot surfaces causing burns; use competent personnel.

Incomplete Combustion Danger

Danger of carbon monoxide from poor combustion.

Water Treatment Chemicals

Operation

General

Boiler Controls

Overview of operating principles for boiler controls.

Filling the Boiler

Starting the Burner

Step-by-step procedure for starting the boiler's burner.

Daily Operating Tests

Procedures for daily visual inspection and safety control tests.

Pump Check

First Low Water Level

Test for the first low water level safety control.

2 nd. (Overriding) Low Water Check

Test for the second, overriding low water safety control.

Blowdown Procedures (Daily tests)

Draining the Boiler

Troubleshooting

Ignition Failure

Common causes and remedies for ignition failure.

Flame Failure

Causes and remedies for flame failure issues.

Boiler Fails to Start

Causes and remedies when the boiler fails to start.

Burner Cut-off

Poor Combustion

Causes and remedies for poor combustion.

Burner Back Fires

Boiler will not maintain pressure

Causes and remedies for the boiler failing to maintain pressure.

Maintenance

General

Importance of regular checks for scale buildup and effective water treatment.

Daily

Weekly (including daily)

Weekly checks including safety valve security and water level controls.

Monthly (including weekly)

Three Monthly (including monthly)

Six Monthly (including three monthly)

Spirax High Integrity Level Controls

Daily Test

Daily testing procedures for the 1st and 2nd low water controls.

Weekly Test (Daily test plus)

Weekly test procedures for low water controls, including evaporation.

Recommended Water Conditions

Feedwater

Recommended water quality parameters for water entering the boiler.

Boiler Water

Recommended water quality parameters for water inside the boiler.

Spare Parts

Ordering Spare Parts Information

Details required for ordering spare parts and safety valves.

FULTON J Series Specifications

General

Model	J Series
Fuel Type	Gas, Oil
Pressure Range	15 - 300 psi
Pressure	15 to 300 PSIG
Pressure Rating	15 - 300 psi
Weight	Varies by model
Dimensions	Varies by model