FULTON J Series, Installation, Operation And Maintenance Manual

Page 1: ...s manual must be available to the boiler operator at all times JGASUK IOMM 2015 2 INSTALLATION OPERATION AND MAINTENANCE MANUAL J Series UK Gas Fired Steam Boiler including optional fully modulating burner ...

Page 2: ...JGASUK IOMM 2015 2 Fulton Ltd Page II ...

Page 3: ...ow Water Level Check 27 4 3 Main Blowdown 28 4 4 Water Column Blowdown 28 4 5 Water Level Gauge Blowdown 29 4 6 Evaporation Checks 30 4 7 Flame Sensor Test 30 4 8 Draining the Boiler 31 4 9 Long Term Shut Down 32 4 10 Internal Inspection 32 4 11 Schedule of Operator Tests and Checks 33 4 11 1 Daily 34 4 11 2 Weekly in addition 34 4 11 3 Monthly in addition 34 4 11 4 Three Monthly in addition 35 4 ...

Page 4: ...e 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 CAUTIONS and NOTES by which hazards are to be eliminated or reduced Personnel must become familiar with all aspects of safety and equipment prior to...

Page 5: ...high temperature surfaces that if touched may cause serious burns Only competent and qualified personnel should work on or in the locality of a steam boiler and ancillary equipment Always ensure the working area and floor are clear of potential hazards work slowly and methodically Do NOT store inflammable materials near the boiler The importance of correct boiler water and feedwater cannot be over...

Page 6: ... containing water level probes Water column blowdown valve Water level gauge sight glass Water level gauge blowdown valves Steam pressure limiter Clean out handhole water jacket Steam pressure control Pressure gauge Air pressure switch Air intake Boiler control panel Control box door lock Control box isolator switch Clean out door furnace ...

Page 7: ...ed Satisfactory performance can only be ensured if the installation recommendations operating routines and maintenance schedules laid out in this manual are adhered to 1 2 TECHNICAL DATA For a full specification refer to Appendix A TI 117 J Series Dimensions Specification CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plan...

Page 8: ...anel Control box door lock Control box isolator switch Clean out door furnace AZL burner control RWF40 PID Controller BT1050 Boiler blowdown timer if fitted BC3150 Blowdown controller if fitted LC3050 Level limiters if fitted Low water level probes Water column containing water level probes Water column blowdown valve Water level gauge sight glass Water level gauge blowdown valves Pressure gauge A...

Page 9: ...nication 1676 and in particular to Section 5 Location of Appliances The boiler house should be sufficiently sized to allow easy and safe access to all parts of the boiler for operational and maintenance purposes Reference should be made to Appendix A TI 117 J Series Dimensions Specification to ascertain the relevant dimensions and weights special note should be taken of the required vertical clear...

Page 10: ...be inserted into the flue outlet in the back of the boiler and secured with the three angle clips supplied loose in the trim box The height and type of flue will be subject to local planning regulations and approvals The following information is only intended to provide assistance for the installation of a simple flue Where multi boiler flues or difficulties are experienced specialist advice shoul...

Page 11: ...lexible connector Condensate return Feedwater pump Feedwater non return valve to be installed below boiler water level Flanged connection 20J 60J only Clean out door Draught stabiliser when fitted Standard boiler trim supplied with boiler Flue Cowl D Diameter of flue H 1 5 X D Feedwater isolation ball valve Pipe safety valve to a safe area using unions and drain as required Steam supply Flue spigo...

Page 12: ...ned so that it is below the internal water level of the boiler and should be installed at least 1 m after the feedwater pump The reason for this placement position is that the check valve is designed to have water on both sides to enable it to function correctly It is essential to protect the feedwater pump from damage by foreign matter a strainer should therefore be fitted in the pump suction pip...

Page 13: ... must be taken to ensure compliance with these regulations If in doubt regarding blowdown arrangements consult Fulton Ltd Note 8J 15J main blowdown connection is via a branch pipe Note 20J 60J main blowdown connection is integral via a boiler mounted flange Where possible the main blowdown pipework on 20J 60J boilers should drop down to a union connection to allow removal of the inspection flange ...

Page 14: ... the water column blowdown valve by 3 8 in soft copper tubing 2 10 GAS SUPPLY Verify that the burner is suitable for the type of gas being supplied Ensure that the piping from the meter is the correct size and that a gas cock is inserted in the line between the boiler and the meter To avoid pressure drops eliminate all unnecessary bends and elbows in the pipework between the gas meter and the boil...

Page 15: ...e the appropriate action should the alarm be activated Unless otherwise specified the alarms supplied will be mains voltage models Unless otherwise specified all models are supplied with burner motors and feedwater pump motors arranged for operation on a three phase supply The power ratings and requirements are given in Appendix A TI 117 J Series Dimensions Specification 2 11 ELECTRICAL REQUIREMEN...

Page 16: ...ional Self Monitoring Controls TDS system Feedwater stop valve Feedwater check valve Burner scroll Steam safety valve Pressure gauge Feedwater line Figure 9 Boiler Top Components non modulating burner Gas train with 360 rotation Air pressure switch Air actuator TDS system Feedwater line Steam out Burner scroll Steam pressure gauge Figure 10 Boiler Top Components fully modulating burner ...

Page 17: ...f either of these tests fail or at any time during boiler operation there is doubt about the integrity of the flue shut down the boiler and contact Fulton Ltd immediately Note Flues that are designed to operate with positive pressure should be tested to the latest regulations 2 13 1 BOILER INSPECTION AND INITIAL FIRING 1 Ensure that the boiler has been washed out after installation It is advisable...

Page 18: ...oiler The operation of the pump controls should be checked by using the boiler blowdown valve located at the rear of the boiler When the water level gauge sight glass is reading two thirds full the pump will stop WARNING Gas purging by qualified persons only 9 After purging the gas lines of air start the burner For models 40J 60J with an external pilot gas line see Section 2 13 2 Setting the burne...

Page 19: ...operating pressure 2 Set the differential scale to it s minimum pressure If the pressure control has a fixed differential i e no adjustable differential scale set the main scale to the maximum pressure required When multiple boilers are fitted with a sequence control 1 Set the main scale and differential scale as above 2 Set the setback pressure control to the required set back pressure Figure 12 ...

Page 20: ...isolating valve 6 Set the gas input to the boiler for correct input on high fire This adjustment should be done where possible by using the gas meter Adjust the main and secondary air gates to obtain optimum combustion conditions 7 Adjust the low fire steam pressure switch to cut out at approximately 5 psi below the setting of the main steam pressure control 8 Adjust the two stage solenoid valve t...

Page 21: ... assembly Main gas line isolating valve Pilot line ball valve Pilot line governor Pilot line gas valves Gas valve Gas governor Gas actuator Figure 13 40J 60J Gas Valve non modulating burner Figure 14 30J 60J Gas Valve fully modulating burner 2 14 MULTI BLOC GAS VALVES ...

Page 22: ...oint connection upstream of Valve 1 Gas input filter cover Test point connection downstream of Valve 1 Adjustable pressure switch Operating indicator Output pressure controller adjusting screw Output pressure controller adjusting screw Hydraulic brake Adjustable pressure switch Operating indicator Test point connection downstream of Valve 1 Gas input filter cover Test point connection upstream of ...

Page 23: ...eak test Test point 2 downstream Test point 1upstream Output pressure controller adjusting screw Operating pressure indicators Figure 16 40J 60J Gas Valve non modulating burner Major Components GAS ACTUATOR GAS GOVERNOR VALVE Servo motor body Valve coupling Gas governor Filter caps Filter main housing Gas out flange Gas valve Electrical connections Low gas pressure switch Gas in flange Figure 17 3...

Page 24: ...e LPG Boilers should be installed to the requirements of IGE UP 10 March 2001 An L P gas boiler is similar in design to a natural gas boiler the main differences are important and must be taken into account when installing the boiler and ordering spare parts When installing an L P gas boiler the feed from the bulk tank supply must be fitted with a supply governor which is set to reduce the supply ...

Page 25: ...en running from the bottom of the casing and from around some branch pipes This is perfectly normal and part of the drying process SECTION 3 OPERATION 3 2 BOILER CONTROLS The following brief description of the controls used on the J series gas fired steam boiler is intended to provide the operator with a basic understanding of the operating principles which is essential for the continued efficient...

Page 26: ...rporating an integral governor pressure switch and gas valves or for larger boilers in addition to the internal components an external pilot line with its own gas solenoid valves and governor For boilers fitted with fully modulating burners a gas actuator is fitted to the gas train PUMP CONTROL Pump Interrupt Pump Run Switch Fitted on the left side of the control panel used to override switch off ...

Page 27: ...eturn to normal water level Ignition Indicates that the ignition transformer has been energised This light will only be illuminated for approximately 5 10 seconds during the ignition sequence Gas Pressure Alarm This light will illuminate whenever the gas is off or below minimum inlet pressure required by the European Standard for gas burners EN676 This switch is factory set and should not be adjus...

Page 28: ...owdown valve s is CLOSED h Ensure the water column blowdown valve is CLOSED i Ensure the Burner and Pump switch is in the OFF position j Ensure all appropriate electrical isolators are switched ON k Ensure the Pump Interrupt switch is switched OFF Pump Run CAUTION The feed pump seals are water cooled The pump must never be allowed to run whilst dry irreparable damage may result Ensure the pump is ...

Page 29: ...d set pressure the main steam isolating valve should be slowly opened allowing steam to enter the system distribution pipework This can be achieved by one of two methods a Crack open the main steam valve and allow the system to heat up slowly minimum 15 minutes before fully opening the main steam valve b Open the main steam valve when starting the boiler allowing the boiler and system to heat up t...

Page 30: ... Water column blowdown valve Water level gauge sight glass Water level gauge blowdown valves Steam pressure limiter Clean out handhole water jacket Steam pressure control Pressure gauge Air pressure switch Air intake Boiler control panel Control box door lock Control box isolator switch Clean out door furnace Feedwater dip pipe Removing replacing water level probe ...

Page 31: ...a blowdown receptacle 4 2 WATER LEVEL AND LOW WATER SAFETY CONTROLS The following procedures ensure the correct functioning of the water level controls and the low water safety controls SECTION 4 MAINTENANCE Tests should be carried out by a competent person trained to perform such tests If any test shows that the equipment is not operating correctly the fault should be investigated and corrected b...

Page 32: ...to observe the water level in the water level gauge and verify that the pump continues to run until the Pump Off level is reached and then switches off 4 2 2 1ST LOW WATER LEVEL CHECK 1 Ensure that the boiler is firing the feedwater pump is not running and that the water level is between Pump On and Pump Off 2 Switch off the pump using the Pump Interrupt Pump Run switch 3 Allow the water level to ...

Page 33: ...r is used 5 Allow the water level to lower further by natural evaporation below the 2nd Low Water level Do not allow the water level to drop below the bottom of the water level gauge 6 Verify that the Low Water Reset switch illuminates If the test fails turn the boiler off and ensure that the fault is rectified before the boiler is used 7 Switch on the pump using the Pump Interrupt Pump Run switch...

Page 34: ...ump interrupt at the Pump Interrupt Pump Run switch 2 Open the water column blowdown valve for 5 seconds 3 Close the water column blowdown valve and wait for 10 seconds for the boiler to refill and the water to stabilise in the vessel 4 Switch the Pump Interrupt switch to Pump Run 1 Start the boiler and generate not more than 10 psi of steam see note 2 Shut off both the burner and the pump Boiler ...

Page 35: ...valve C 5 Open valve C 6 Close valve A Repeat for gauge set 2 On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves are CLOSED Note Where a boiler is operating continuously at steam pressure advice should be taken from Fulton Ltd as to the appropriate blowdown procedure WORKING POSITION STEAM BLOWDOWN WATER BLOWDOWN A A A B B B C C C Operating Po...

Page 36: ...minate When the check is complete proceed as follows c Switch the pump ON at the pump interrupt pump run switch d Press the low water reset switch The pump will start to refill the boiler If the pump starts to run at any time during the test then the test must be abandoned and restarted from the beginning 4 7 FLAME SENSOR TEST This test checks the operation of the flame safeguard sensor 1 Ensure t...

Page 37: ...n steam valve and the boiler drain valve 5 Open the drain valve on the blowdown vessel 6 Open all valves in the drain lines Boilers with automatic blowdown systems 1 The boiler should not be under pressure 2 The boiler should be cold 3 Close the blowdown isolation valve 4 Using a screwdriver located as shown A push up and make a quarter turn this will lock the button in position and open the blowd...

Page 38: ...stall a string of outdoor type waterproof light bulbs distributed throughout the boiler 4 10 INTERNAL INSPECTION The lower hand hole doors should be removed after one month of operation and the interior of the boiler thoroughly examined If scale or sludge build up is observed it should be removed and the water treatment supplier advised New gaskets must be fitted every time a hand hole door is rem...

Page 39: ...immediately and consult Fulton Ltd 4 11 SCHEDULE OF OPERATOR TESTS AND CHECKS The following schedule is the advice of Fulton Ltd The frequency of tests and checks may vary according to site risk assessment and or specific requirements of the country territory that the boiler is installed in Failure to maintain the boiler adequately may void the Fulton warranty Maintenance on gas related parts of a...

Page 40: ...not operate the safety valve without protection 5 Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe blowdown point 6 Pump Test see Section 4 2 1 7 First Low Water Check see Section 4 2 2 8 Second Low Water Check see Section 4 2 3 9 Flame Sensor Test see Section 4 7 WARNING Ensure the main electrical supply is isolated before starting work 10 Visually ...

Page 41: ...out door use new gasket material and furnace cement to ensure a tight seal subsequently preventing the escape of hot gases 19 Apply a small quantity of oil to the bearings of the burner motor and the feedwater pump motor 20 Drain and flush the feedwater tank Clean any filters in the tank in the feedwater line or in the feedwater pump 21 Remove and clean the water level probes take care not to crac...

Page 42: ...re that excess air and carbon monoxide values are within normal limits see combustion values in Appendix A TI 117 J Series Dimensions Specification 27 Check the condition of the gas valve filter if fitted renew as required Cleaning the Flues Remove cover plates and gasket Remove the clean out door to the flue passes and to the bottom of the boiler Oil boiler illustrated Figure 29 Flue Cleaning Fig...

Page 43: ...Fulton Ltd Page 37 MAINTENANCE 4 Figure 32 Burner Plate Figure 33 Burner Assembly 4 11 6 ANNUALLY IN ADDITION 28 Fulton Ltd recommend replacement of all threaded stub pipes on the boiler OR to your inspectors satisfaction ...

Page 44: ...aker Reset or replace as required 2 Gas supply Check for gas pressure and intermittent supply problems 3 Air Settings Check main air adjustment and secondary air adjustment 4 Ignition Electrodes Check electrodes for carbon build up Clean as required Check for proper adjustment readjust if necessary Check for cracks in porcelain if found replace the electrode 5 UV Detector Check the detector is loc...

Page 45: ... draft value for your system 6 Dirty Flue Check flue for carbon build up or blockage Clean the flue 7 Negative Room Pressure Ensure there are no exhaust fans running in the boiler room 8 Dirty Fan Check fan for obstructions clean as required Burner Back Fires 1 Refractory Bricks Check refractories to see if they are plugged with soot Delayed Ignition or broken in pieces Clean or replace as necessa...

Page 46: ...Check steam traps clean or replace as required 2 Contamination in boiler Empty boiler and feed tank Flush out and refill if system operates but progressively deteriorates there is probably a leak somewhere in the system 3 Scale buildup or lime deposits Consult Fulton or call a water treatment specialist 4 Too much compound water treatment over dose Dump contents of the return tank and flush the sy...

Page 47: ...overload trips out occasionally 1 Overload setting is too low Set the overload correctly 2 Low voltage at peak times Check the electricity supply Motor contactor has not tripped out but the pump does not run Check Motor does not run when started items 1 2 4 5 6 Pump capacity not constant 1 Pump inlet pressure is too low cavitation Check the suction conditions 2 Suction pipe pump partly blocked Cle...

Page 48: ...ing water passed Water pump will not come on at times 1 Scale on probes Check and clean probes replace as necessary 2 Faulty pump contactor Check the contactor has power Check the contactor is pulling in Replace if necessary 3 Faulty pump motor Check the pump has power If the pump has power but is not running replace it 4 Faulty Level Control Relay Check the relay has power and is secure on it s b...

Page 49: ... air pressure failure after this time will cause a lockout condition Lockout 3 Flame supervision Check for stray light cell only Faulty cell or damaged flame probe Interruption of start up sequence 1 Air Damper Check low fire microswitch is made Lockout 1 No ignition spark Check supply ignitor Check electrode and HT leads for damage 1 2 No pilot flame Check gas supply Check electrode setting Check...

Page 50: ...ressure at burner Check flame signal strength refer to LFL1 data sht 7451 2 Lockout 1 Flame failure Check flame signal l 2 Air pressure failure Check switch operation Lockout on completion of control programme sequence 1 Extraneous light Check flame extinguished Check gas valves for leaks 2 Faulty flame signal Check for aged faulty UV cell Check flame supervision circuit 4 12 3 TROUBLESHOOTING BUR...

Page 51: ...JGASUK IOMM 2015 2 Fulton Ltd Page 45 MAINTENANCE 4 Date Action Remarks Sig 4 13 MAINTENANCE LOG This log should be completed regularly as a record of boiler maintenance ...

Page 52: ...10 Flame failure device tested Y N 5 Blowdown Boiler Duration seconds Self Monitoring Controls if fitted Test Time 6 Blowdown Water Column Duration seconds 11 First Low Water Level Burner cut out and alarm sound Y N Test Time 7 Blowdown Water Level Gauge Duration seconds 12 Second Low Water Level Burner cut out alarm sound Y N Test Time Pressure gauge reading for blowdown tests 13 Pressure gauge r...

Page 53: ...ton TI sheets These TI sheets can be found in this Appendix Note The TI sheets in this appendix can be updated replaced without revising the manuals issue number To check you have the most up to date TI sheet please check the downloads section on the Fulton website www fulton co uk support downloads or consult Fulton Ltd ...

Page 54: ...JGASUK IOMM 2015 2 Fulton Ltd Page 48 APPENDIX A ...

Page 55: ...Oil Inlet Height 1550 1640 1735 1915 2150 L Safety Valve Discharge Height 1840 1930 2060 2240 2490 M Steam Outlet Height 1845 1950 2100 2310 2680 N Feedwater Inlet Height 1810 1900 2030 2210 2460 P Flue Outlet Height 1500 1565 1670 1820 2075 R Flue Diameter 152 203 255 305 305 S Main Boiler Blowdown Height 380 380 390 390 395 T Control Column Blowdown Height 1025 1115 1245 1385 1670 U Water Level ...

Page 56: ... 50 50 50 50 50 Max LPG mbar 80 80 80 80 80 80 80 80 Firing Rate Gas m3 h 7 0 9 3 11 6 17 4 23 2 34 8 58 1 69 6 Oil L h 7 1 9 4 11 8 17 6 23 6 35 2 58 9 70 4 LPG Propane m3 h 2 9 3 9 4 8 7 2 9 6 14 4 24 1 28 9 Ventilation Requirements for Combustion Purposes Free Area Low Level inlet cm2 670 800 920 1250 1570 2220 3530 4170 High Level Outlet cm2 335 400 460 625 785 1110 1765 2085 Electrical Requir...

Page 57: ...ulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England FM 28400 003 FM 28400 Note Dimensions mm Note Dimensions are approximate and only intended as a guide to aid installation 216 High Water Probe 216 241 405 430 Pump Off Pump On 1st Low Water 2nd Low Water Centre of Glass Top of Sockets Shell Furnace DATUM underside of probe hex head 2nd Low Water 1st Low Water Probe Lengths High Level 216...

Page 58: ...JGASUK IOMM 2015 2 Fulton Ltd Page 52 APPENDIX A ...

Page 59: ...Organic Matter Less than 5 mg kg Oil None Minimum Temperature 85 C BOILER WATER water inside boiler pH Value 9 5 to 11 5 tested at room temperature Hardness Not detectable Suspended Solids Less than 100 mg kg Chloride Less than 500 mg kg Oxygen Scavenger Sodium Sulphite or Tannin 20 to 50 mg kg Phosphate Less than 50 mg kg in the form of PO4 Total Alkalinity Less than 1000 mg kg Caustic Alkalinity...

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Page 61: ...Terminal Nut would require adjustment and therefore cause the probe to leak see Figure 35 N B The Probe Rod Grub Screw and Lock Nut are suitably tightened during manufacture meaning the probe is ready to be installed without any adjustment The ONLY instance a spanner should be used is to turn the Probe Body in order to remove or reinstall the entire probe IMPORTANT Terminal and securing nuts must ...

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Page 63: ...Damper Motor High Low Fire Cams Air Damper Housing 1 2 OPERATION With the steam pressure switch pre set to the high and low fire operational requirements of the system and the boiler operating normally steam pressure will gradually increase until the high pressure limit is reached the pressure switch will then switch the two stage gas valve and the air damper motor to the low fire position The boi...

Page 64: ... INPUT RATES Commissioning should be carried out by a qualified Fulton Service Engineer To achieve the ideal combustion efficiency and gas input rates a gas flow rate meter is required to measure the fuel input to the boiler 1 4 2 AIR DAMPER MOTOR FACTORY CAM SETTINGS Terminal Position Degrees N1 High Fire Motor Cam 45 N2 Low Fire Motor Cam 10 N5 High Fire Interlock Cam 40 N6 Low Fire Interlock Ca...

Page 65: ...ncrease the amount of air entering the boiler switch the low fire hold switch off When the motor has driven back to high fire turn the low fire hold switch on the damper will drive back to its new low fire position Adjust the cams until the correct CO2 figure is achieved Note Any adjustment to the cam positions requires an adjustment to its interlock cam position 4 Switch off the low fire hold swi...

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Page 67: ...lation with a weekly test by interrupting the feedwater pump and lowering the water by evaporation 1 1 1 1ST LOW WATER DAILY 1 1 2 2ND LOW WATER DAILY 1 Press and hold the 1st Low Water test button 5 6 seconds the Low Water alarm sounds and the Low Water indicator lamp illuminates and the burner shuts down 2 Release the test button 3 After approximately 17 seconds the Low Water alarm will cancel t...

Page 68: ...nd Low Water Reset switch illuminates and the burner shuts down 3 Switch the Pump Interrupt switch to the Pump On position 4 The pump will start and restore the water level to the normal position and switch off 5 After approximately 17 seconds from restoring the 2nd Low Water level the 2nd Low Water Relay can be reset 6 To cancel the 2nd Low Water Level alarm and light depress the 2nd Low Water Re...

Page 69: ...e sample value is higher than the control value the blowdown solenoid valve opens in a series of pulses until the measured value corresponds to or is lower than the set value When this is achieved blowdown finishes until the next timed sample is taken when the process is repeated Should the sample value be lower than the set value blowdown is deferred until the next timed sample For the system to ...

Page 70: ...r acknowledgement Further re calibration will be required until the water treatment regime has been established and typical water conditions have been achieved Routine calibration checks will be required as part of the site maintenance and water treatment monitoring The equipment staff training required to carry out TDS sampling and calibration can be provided by Fulton if required In order to ach...

Page 71: ...by you In all cases at the termination of such 12 months all liability on our part will cease No liability whatsoever is to be incurred by us in respect of gauge or sight glasses packing glands or electric motors or any goods or accessories not of our manufacture But so far as we are able we shall let you have the benefit of any guarantee or warranty given to us in respect thereof On the Fulton Bo...

Page 72: ...www fulton co uk Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England Telephone 44 0 117 972 3322 Fax 44 0 117 972 3358 Email sales fulton co uk FM 28400 003 JGASUK IOMM 2015 2 ...