FULTON J Series - User Manual

Other manuals for FULTON J Series

Installation, Operation And Maintenance Manual76 pages

Questions and Answers

S
smithrachelSep 2, 2025
Why is my FULTON Boiler surging, with a widely fluctuating water level?
- J
  Joseph SmithSep 2, 2025
  A surging FULTON Boiler, indicated by a widely fluctuating water level in the sight glass, can be attributed to several causes. Start by checking the steam traps, cleaning or replacing them as required. Contamination in the boiler can also lead to surging; empty the boiler and feed tank, flush out, and refill. If the system operates but progressively deteriorates, there is probably a leak somewhere in the system. Other causes may include scale buildup or lime deposits, too much compound (water treatment over dose), or high alkalinity (high pH). Finally, the load may exceed the boiler capacity; check the total system load against the boiler's output and decrease the load required at any one time.
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Theodore MorenoSep 3, 2025
Why does my FULTON J Series Boiler rumble and pulsate?
- J
  Jessica KnightSep 3, 2025
  If your FULTON Boiler rumbles and pulsates, this could be due to poor combustion, so check combustion readings. It may also be caused by the draft, so check draft with a gauge. Draft should be -.05 to -.1 mbar with the burner off. A barometric damper may need to be installed. Too much main air can also be a cause, so adjust main air gate.
K
Kevin NewmanSep 4, 2025
Why is my FULTON J Series Boiler carrying over water with the steam?
- J
  James ValenciaSep 4, 2025
  If your FULTON Boiler is carrying over water with the steam, it could be due to several reasons. First, check the steam traps, clean or replace as required. Also, consider if there is too much compound (water treatment over dose) in the system; if so, dump contents of the return tank and flush the system, then test the water. Finally, check for contamination in the boiler; empty the boiler and feed tank, flush out and refill. If the system operates but progressively deteriorates, there is probably a leak somewhere in the system.
C
Charles BarnettSep 5, 2025
What should I do if the feedwater pump of my FULTON J Series Boiler will not run?
- S
  Sarah VillarrealSep 5, 2025
  If the feedwater pump of your FULTON Boiler will not run, first ensure the electricity supply is connected. Check and replace any blown fuses or tripped circuit breakers. Reactivate the motor protection if the motor contactor overload has tripped. Inspect the contactors to ensure they are making, checking for a faulty coil or loose wiring. If the control circuit is defective, repair it. Finally, if the motor is defective, replace it.
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Eric SmithSep 6, 2025
Why does the motor starter overload trip immediately when I switch on my FULTON J Series Boiler?
- P
  Paige ThomasSep 6, 2025
  If the motor starter overload trips out immediately when you switch on your FULTON Boiler, it could be due to several reasons. One possible cause is a blown fuse or automatic circuit breaker, so replace the fuse or reset the circuit breaker. Another cause could be faulty contacts in the motor contactor overload, so replace the motor starter contacts. A loose or faulty cable connection could also be the problem, so tighten or replace the cable connection. Additionally, a defective motor winding could be the cause, so replace the motor. A blocked pump could also cause the overload to trip, so remove the blockage. Finally, the overload setting may be too low, so set the motor starter correctly.
D
Dean LopezSep 7, 2025
Why does the motor contactor overload in my FULTON J Series trip out occasionally?
- T
  thomas65Sep 7, 2025
  If the motor contactor overload in your FULTON Boiler trips out occasionally, it could be because the overload setting is too low, so set the overload correctly. Another possible cause is low voltage at peak times, so check the electricity supply.
A
Alison BeardSep 8, 2025
What causes inconsistent pump capacity in my FULTON J Series Boiler?
- B
  Barry SanchezSep 8, 2025
  Inconsistent pump capacity in your FULTON Boiler can be caused by several factors. The pump inlet pressure might be too low, leading to cavitation, so check the suction conditions. The suction pipe or pump could be partly blocked, so clean the pump or suction pipe. The pump may also be drawing in air, so check the suction conditions.
A
Andrew RodriguezSep 8, 2025
What to do if my FULTON J Series Boiler's pump runs but gives no water?
- T
  Theresa PatelSep 9, 2025
  If your FULTON Boiler's pump runs but gives no water, first check if the suction pipe or pump is blocked, and clean them if necessary. Inspect the foot or non-return valve for blockages in the closed position and repair it. Look for any leakage in the suction pipe and repair it. Check for air in the suction pipe or pump and verify the suction conditions. Ensure the pump rotates in the correct direction by changing the motor's rotation direction if needed. Finally, inspect the boiler feedwater non-return valve to ensure it is seating properly and not allowing water to pass, which is usually accompanied by banging in the feedwater tank; clean the valve if necessary.
A
Adam BlevinsSep 9, 2025
Why does the pump in my FULTON Boiler run backwards when switched off?
- D
  Derrick StrongSep 9, 2025
  If the pump in your FULTON Boiler runs backwards when switched off, it could be due to leakage in the suction pipe, so repair the suction pipe. It could also be that the foot or non-return valve is defective, so repair the foot or non-return valve.
D
Daniel WatsonSep 12, 2025
What causes excessive noise in my FULTON J Series Boiler's pump?
- G
  gutierrezzacharySep 12, 2025
  Excessive noise in your FULTON Boiler's pump can be caused by cavitation, so check the suction conditions. It may also occur if the pump does not rotate freely due to frictional resistance from an incorrect pump shaft position, so adjust the pump shaft. Boiler feed water non-return valve letting water passed the valve seat, (normally accompanied by banging in the feed water tank), check and clean boiler feedwater non-return valve, ensure it is seating and not allowing water passed.

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