Fulton Edge ICX or FB-F Vertical Tubeless Boilers (Steam), Gas Fired - Manual (Page 64)

Furnace Refractory Replacement
Procedure
a) Remove the burner plate and top
plate assembly up and out of the scroll
assembly.
b) Remove the stainless steel com-
bustion ring from the furnace
(50 and 60 HP only).
c) Remove the clean-out plugs from
the bottom sides of the boiler.
4-15 HP boilers have one clean out
plug located at the bottom of the boiler
directly below the panel box. 20-60
HP boilers have one clean out plug
located at the bottom of the boiler to
the right side of the panel box. 10-30
HP Energypak Boilers have one clean
out to the right of the lower right side
hand hole and one clean out to the
right of the rear bottom blow down.
d) Break off the top holding clips that
were used to keep the refractory in
position during shipping. The 4-50 HP
boilers also have holding clips beneath
the top refractory. There is no need to
cut the holding clips located beneath
the top refractory as the refractory may
be rotated to avoid these clips during
installation of the lower refractory. The
60- HP boiler has welded flat bars
beneath the top refractory. These bars
will have to be cut to change the lower
refractory. Rewelding of the bars will
be required prior to installation of the
top refractory. For the lower refractory
you will also need to break off the top
holding clips that were used to keep
the refractory in position during ship-
ment.
e) Break up the top and/or bottom
refractories and remove the pieces
from the boiler through the clean-out
plugs.
NOTE
If only the top refractory is to be
changed, the bottom refractory
need not be broken.
f) Round and bevel the outer edges of
the new refractories.
g) The bottom refractory has the
largest hole, while the top refractory
has the smallest.
h) Lower the bottom refractory down
the furnace with wire fastened around
the refractory in three positions. When
the refractory is close to position, it can
be tipped by maneuvering the wire to
drop it flat on the holding clips. If the
refractory will not tip, it may have to be
removed and again rounded and
beveled.
i) Install the top refractory in the same
manner as the bottom refractory.
When installed the outer edges must
be sealed with insulcrete - a castable
refractory mix available from the
Fulton factory.
It is not necessary to reinstall the ship-
ping clips.
j) Install the stainless steel combus-
tion ring, (50-and 60 HP only) burner
assembly, and clean out plug.
k) normal operation can be resumed
immediately.
55-G 1/01
Maintenance
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Stainless Steel Ring
Supporting Clips
Air
Deflector
Gas Orifice
Assembly
Stainless Steel
Combustion
Chamber
Ring
Stainless Steel
Supporting Clips
Top Castable
Refractory
Bottom
Castable
Refractory
Stainless Steel
Supporting Clips
Holding Clips For
Shipping Only
Holding Clips For
Shipping Only
Gas Train
Assembly