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INSTALLATION, OPERATION, MAINTENANCEAND PARTS MANUAL

JGAS-E-10 2008

'J' SERIES - GAS FIRED

STEAM BOILERS (6J - 60J)

This Manual must be available to the boiler operator at all times.


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The Pressure Sstem Safet Regulations 2000

Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme.

Regular inspections are therefore required by a 'Competent Person'.

The scope of the examination and the actual intervals between examinations is at the discretion of the com-

petent person.

It is the responsibility of the user to provide a written scheme of examination for those parts of the system in

which a defect may give rise to danger.

Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover

periodic statutory inspections.

For further information contact:-

(a) SAFed

SAFETY ASSESSMENT FEDERATION Limited.

Nutmeg House,

60 Gainsford Street,

Butlers Wharf,

London, SE1 2NY.

(b) HealthandSafetyExecutivelocalofce.

(c) Your Competent Person.

IN CASE OF EMERGENCy

This boiler has been designed and constructed to meet all of the essential requirements of the applicable

European Directives and subject to proper maintenance should not give occasion to an hazardous

conditions. If such a condition should occur during commissioning or during subsequent operation of

this product, what so ever the cause, then the fuel suppl to the boiler should be isolated immediatel,

until such time that the fault has been investigated by a competent person and rectied.

WARNING

Steam Boilers are a potential hazard, possibl

fatal if not properl maintained.

CAUTIONIt is vitall important that the instructions given

in this manual are strictl adhered to.

Failure to carr out the routine maintenance checs could result

in a drastic reduction in the life expectanc of the boiler.

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 effectiveness.

NOTES must be 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 ofsafety and equipment prior to operation or

maintenance of the equipment.

For your Safet!

The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.


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LIST OF CONTENTS

TITLE SECTION

INTRODUCTION 1

General 1.1

TechnicalData(forafullspecicationrefertosection5) 1.2

INSTALLATION 2 General 2.1

Siting 2.2

Ventilation 2.3

Flue Outlet 2.4

WaterSupply(seealsoWaterTreatmentinsection5) 2.5

Blowdown Valves 2.6Main Steam Valve 2.7

Steam Safety valves 2.8

Water Gauge Set 2.9

Gas Supply 2.10

Gas Valve, Pilot Gas (40 - 60 models & Australia) 2.10.1Electrical Requirements 2.11

Steam Pressure Gauge 2.12

Commissioning the Boiler 2.16

Boiler Inspection and Initial Firing 2.16.1

Setting the Burner Controls for Low Fire/High Fire, Models 40-60 2.16.2

Multibloc Gas Valves 2.17Cleaning Steam Lines and Pressure Vessel 2.18

Gas Supply - Propane/Butane 2.19

OPERATION 3

General 3.1

Boiler Controls 3.2Control Panel - Indicator Lights 3.3

Filling the Boiler - All Models 3.4 StartingtheBurner-AllModels 3.5

Daily Operating Tests 3.6

Pump Check 3.6.1

First Low Water Level Check 3.6.4 SecondLowWaterCheck 3.6.5

Blowdown Procedures 3.7

Evaporation Checks 3.8

Troubleshooting - Boiler 3.9

Troubleshooting - Burner Control Unit LFL - 1 3.10Troubleshooting - Burner Control Unit TMG 740-3 3.11

Draining the Boiler 3.12

Long Term Shut Down 3.13

Maintenance Log

MAINTENANCE 4

General 4.1

Daily 4.2

Weekly 4.3

Monthly 4.4

ThreeMonthly 4.5Six Monthly 4.6

GENERAL DATA 5

Boiler Dimensions

BoilerSpecication

Recommended Water Conditions

Probe LengthsWiring Diagrams

Pressure Controller

Boiler Controls Test Log


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SAFETyThe instructions provided for the operation and maintenance of the boiler MUST be observed.

Failure to do so could result in damage to the boiler and serious personal injury.

WARNINGDo not try to do repairs or any other maintenance

work you do not understand. Obtain a Service Manual from

Fulton or call a Fulton Service

Engineer

WARNINGIt is the responsibility of the installer to ensure all parts supplied

withtheboilerarettedinacorrectandsafemanner.

WARNINGUnderstand the electrical circuit before connecting or discon-

necting an electrical component. A wrong connection can

cause injury and or damage.

WARNINGA defective boiler can injure you or others. Do not operate

a boiler which is defective or has missing parts. Make surethat all maintenance procedures are completed before us-

ing the boiler.

CAUTIONObey all laws and local regulations which affect you and

your boiler.

WARNINGDo not change the boiler fuel without consulting the boiler

manufacturer.

WARNINGLIFTING EQUIPMENT

Make sure that lifting equipment complies with all local regu-lations and is suitable for the jobYou can be injured if you

use faulty lifting equipment. Make sure the lifting equipment

is in good condition.

WARNINGOperating the boiler beyond its design limits can

damage the boiler, it can also be dangerous.

Do not operate the boiler outside its limits.Do not try to up grade the boiler performance by unapproved

modications.

WARNINGNon-approvedmodicationscancauseinjuryanddamage.

Contact your Fulton dealer before modifying the boiler.

WARNINGOnly qualied persons should be allowed to

operate and maintain the boiler and its equipment.Boilers

should always be drained through an approved Blowdown

Vessel.

WARNINGTheinstallationofGasappliancesincludingtheuesystem

should only be carried out by Corgi

Registered Enginee

CAUTIONHYDRAULIC TEST - RISK OF BRITTLE FRACTURE

Hydraulic testing requires specialist equipment and is nor-

mally only required by engineering surveyors / inspectors.

The material the boiler is manufactured from, has not been

impact tested, as it is not a requirement of BS2790 (boiler

constructionstandard). In order to ensure the material / pressure vessel

does not suffer from brittle fracture,

hydraulic testing should not be carried out

below 7OC.

WARNINGDANGER FROM HOT SURFACES

Steam Boilers have high temperature surfaces, that if touchedmay cause serious burns. Onlycompetentandqualiedpersonnelshouldworkonorinthe

locality of a steam boiler and ancillary equipment. Always

ensure the working area and oor are clearofpotential

hazards, work slowly and methodically.

DoNOTstoreinammablematerialsneartheboiler.

WARNINGDANGER FROM INCOMPLETE COMBUSTION

The importance of correct burner adjustment to achive low

emissions,safe,cleanandefcientcombustionisparamount.

Poor combustion, where unburnt gas forms carbon monoxide

is both a health hazard, and the potential risk to the boiler

from overheating, caused by re-burning of the unburnt gasinthesecondaryuepasses.

WARNINGThe importance of correct boiler water and feed water can-

not be over emphasised, see the relevant section in this

manual.

CAUTIONLOW FEED WATER TEMPERATURE

Low feed water temperature can result in thermal shock to

the boiler pressure vessel. Return the maximum amount of

condensate and if necessary pre-heat the feed water. If in

doubt consult FBW.

CAUTIONWATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners and

chemical treatment plants are NOT SUPPLIED by Fulton.It is the responsibility of the operator to ensure adequate

supplies of chemical are available at all times (including

commissioning).

Costly repairs could be required should the plantoperate without chemicals or the wrong dosage of

chemicals.


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FIG.1 GAS FIRED STEAM BOILER

1 1

1

Supply Gas,

Pressure Test Point Steam

Pressure

Gauge

Feed Water Isolating

Ball Valve

Feed Water

Non-return

Valve

Steam Supply

Valve

Air Pressure

Switch

Air Intake

Manifold

containing

Main Air

Control

Boiler Control

Panel

Control Box

Door Lock

Control Box

Isolator Switch

Steam Pressure

Control

Clean Out Door

(Gas turn around)

Clean Out Handhole

(Water Jacket)

Boiler

Blowdown Valve

Water Column

Blowdown Valve

Feed Water Pump

Isolator Switch

Sight Gauge

Blowdown

Valves

Safety Valve

Water Columncontaining

water level

probes

Scale Trap

Gas Inlet

Gas Supply Valve

Monobloc

Gas Valve


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1

INTRODUCTION

SECTION 11.1 General (Fig. 1)

The J Gas Service Manual is a generic publication, as such provides information on standard boiler

operation and maintenance.

TheFultonJSeriesGasFiredSteamBoilerisaverticaltwopassboilerofsimpleandefcientdesign

and construction. Every care has been taken in the manufacture of the boiler to ensure that quality

and reliability standards are maintained. However, 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 - Boiler Output

forafullspecicationrefertoSection5.

1

BOILER MODEL 6J 8J 10J 15J 20J 30J 40J 50J 60J

Output

kg/h (F & A 100oC) 96 128 160 240 320 480 640 800 960

CAUTIONWATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners and chemical treat-

ment plants are NOT SUPPLIED by Fulton.

It is the responsibility of the operator to ensure adequate supplies of chemi-

cal are available at all times (including commissioning).

Costly repairs could be required should the plant operate without chemicals

or the wrong dosage of chemicals.

2


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FIG. 2 GENERAL ARRANGEMENT

2

Gas Cock

Modular

Gas Unit Pressure

Test Point

Main Steam

Valve

Steam Safety

Valve

Water

Column

with water

level probes

Air Safety

Switch

Blower

Housing

containing

Main Air

Control

Burner

Motor

Steam Pressure Gauge

Scale Trap

Blowdown

Valve

Water

Gauge

Sets

Operator

Control

Panel

WaterColumn

Blowdown

Valve

Pressure

Control

Hand Hole

(Water Jacket)

Clean Out Door

(Gas turn around)

Main

Boiler

Blowdown

Valve

Feed Water IsolatingBall Valve

Check Valve

2

3


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2

INSTALLATION

SECTION 22.1 GENERAL

The installation of a J Series Gas Fired Steam Boiler should be carried out by competent personnel

in accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that

these regulations are complied with.

The requirements and instructions contained in this Section generally relate to the boilers being

installed to operate on natural or manufactured gas. Where the boiler is to operate on L.P. Gas,

special reference should be made to Section 2.10 - Gas Supply, and Section 2.18 L.P. Gas Supply.

2.2 SITING ( Reference should be made to Utilization Procedures as stated in IGE/UP/10 Part 1

Communication1676,andinparticulartoSection5,LocationofAppliances).

Theboilerhouseshouldbesufcientlylargetoalloweasyandsafeaccesstoallpartsoftheboilerforoperational and maintenance purposes.

ReferenceshouldbemadetoSection5-GeneralDatatoascertaintherelevantdimensionsand

weights, special note should be taken of the required vertical clearance required for maintenance.

WARNING

Maintenance on the burner assembl requires the area directl above

and to one side of the boiler must not be obstructed with pipewor or

equipment which would interfere with the removal of the complete burner

unit. Care should be taen on installation of the boiler to ensure this

area remains clear of obstructions.

Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthtosupportthe boiler.

2.3 VENTILATION

Adequatefresh,cleanairisnecessaryforsafeandefcientcombustion,andshouldbeprovidedat

high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part 1 Communication 1676.

Note:

(a) Ensurethereisadequateventilationintheboilerroom.Lackofventilationwillcreatea

hightemperatureandcausecontrollockout.

(b) Donotkeepexhaustfansrunningwithwindows,doorsandventsclosed,thiswillinterfere

withthenecessaryboilerdraught.

(c) Donotstorechemicalssuchasperclorethyleneintheboilerhouse,thefumesmay

damagetheboilerandueandcausetheburnertolockoutonamefailure.

Note: seesection5forLowandHighLevelvalues.

2

4


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FIG. 3 TyPICAL INSTALLATION

2 2

F

03164

SteamSupply

Pipesafetyvalve

toasafearea,

usingunionsand

drainas

required.

Feedwaterisolationballvalve

Feedwaternon-return

valve

Standardboilertrim

suppliedwithboiler

Note:Abreaktankmayberequireddepending

uponLocalWaterAuthorityBy-laws

Stainlesssteel

feedwaterand

condensate

returntank

Vent Blo

wdown

Separator

Overflowto

drain

Make-upfee

dwatersupply

Drain

Pluggeddrains

Isolatinggate

/ballvalve

Strainer

CondensatereturnF

lexiblelink

Overflow

Draughtstabiliser

(whenfitted)

Clean-outdoor

Fluespigot

Boilerblowdownvalve

Waterco

lumn

blowdow

nline

Flangedconnection

20-60Jonly

Fee

dwater

pump

D

H

D=Diame

terofflue

H=1.5

XD

Flue

Cowl

5


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2

2.4 FLUE OUTLET

Theboilerissuppliedwithastainlesssteeluespigot

thatshouldbeinsertedintotheueoutletinthe

back of the boiler and secured with the three angle

clips supplied loose in the trim box.

Theheightandtypeofuewillbesubjecttolocal planning regulations and approvals. The following

information is only intended to provide assistance for

theinstallationofasimpleue.

Wheremulti-boileruesordifcultiesareexperienced,

specialist advice should be obtained.

Theuediametermustbethesameorlargerthan

theueangeprovidedwiththeboilerandthe

outlet should be at least 1 meter higher than the

nearest ridge to avoid down draughts. Where a

chimneycowlistted,careshouldbetakentoensure

that the distance between the lowest point of the cowl andthetopoftheueis1.5Xthediameteroftheue.

and that it is of the terminal cone type.

Note:

1. Iftheuelayoutissuchthatitmayproduceanexcessiveup-draught,adraughtstabiliser

mayberequired.

2. Avoidtting90deg.elbowswheneverpossible,ifunavoidablecompensatebyincreasingthe

uediameter.

3. Ensurealluepipesfromtheboilertothemainuehavearisingpitch.

2.5 WATER SUPPLy

The quality of the water used in the boiler will affect the life and performance of the boiler. Feed water

contains solids and dissolved gases, these may promote encrustations of scale; foaming, priming,

surging; corrosion and pitting; or caustic embrittlement. To prevent this happening it is strongly

recommended that a reputable water treatment concern is consulted prior to commissioning the

boiler.

Note:seeSection5WaterTreatment.

Connect the feed water pump to the check valve

inletwith25mm.borepipe(thismaybereduced

to15mm.wherethedischargepipeworkisshorter

than 4m in total), the pump suction pipe work must

remainat25mmminimumdiameter.)andinsertthe

stop valve supplied, between the boiler and thecheck valve.

It is essential to protect the feedwater pump from

damage by foreign matter, a strainer should

thereforebettedinthepumpsuctionpipework

Care should be taken to ensure the pipework is

properly aligned and not placing any strain upon

the feed water pump.

Note:

1. Theboilerfeedwaterpumpmaycontain

aninhibitorandthisshouldbeushedfromthepumppriortottingthepumptotheboiler.

Failuretodosomayresultinwaterbounceorfoamingduetotheinhibitorforming asealin

theboiler. 2. Iftheboileristobeoperatedwithlittleornocondensatereturn,considerationshouldbegiven

topre-heatingthefeedwater.IfindoubtconsultFultonBoilerWorks.

3. TheFeedwaterinletconnectiononsomeboilersislocatedonthelefthandsideoftheboiler

belowthesightglassassembly.

FIG. 4 BOILER FLUE CONNECTION

FIG. 5 BOILER FEED WATER ARRANGEMENT

Check

Valve

Feed

Water

Supply

Isolating

Ball Valve

2

6


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2.6 BOILER BLOWDOWN VALVES

There are three blowdown valves on the boiler

(fouriftwowatergaugesetsaretted),the

boiler blowdown valve at the rear of the boiler,

the water column blowdown valve and the

water gauge blowdown valve.

All of these valves must be connected to a

blowdown receptacle of approved design.

Regulations exist covering such items and

care must be taken to ensure compliance with

these regulations. If in doubt regarding blow

down arrangements, consult your Fulton

agent.

Note:6J-15Jmainblowdownconnectionviabranch

pipe 20J - 60J main blowdown connection is integral,

viaaboilermountedange.

FIG. 6 BOILER BLOWDOWN (models 20-60)(skid mounted boiler shown)

2

7

FIG. 7 BOILER BLOWDOWN (models 6 - 15)

2

(skid mounted boiler shown)


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WATER COLUMN BLOWDOWN VALVE

(Australian boilers onl).

The valve is a three position isolation valve,

each position is indicated on a backing

plate mounted with the valve,

(the valve is shown in the blowdown position).

FIG. 8A WATER COLUMN SEQUENCING and

BLOWDOWN VALVES

(Australian boilers onl)

2

8

2

Water Column

Blowdown Valve

FIG. 8 WATER COLUMN BLOWDOWN VALVE

2.6.1 WATER COLUMN BLOWDOWN VALVE

The valve on the water column should be operated

daily to blowdown the column.


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FIG. 9 BOILER TOP COMPONENTS

9

2

Main Gas Valve

Air Proving Switch

Boiler Water Level Probes

Gas Train

with 360O rotation

Water Feed

with Stop Valve andCheck Valve

Note: Boilerillustratedisttedwithop-tional Self Monitoring Controls.

Flame (UV) Detector

Secondary Air Control

Secondary Air Control

2


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2.7 MAIN STEAM VALVE

Themainsteamstopvalveshouldbeinsertedinthesteamlineapproximately12in.(305mm)fromthe

top of the boiler.

2.8 STEAM SAFETy VALVES

SafetyValvesarefactoryttedandpreset,theyMUSTNOTbeadjusted.Thedischargeoutlet

should be piped to a safe discharge point and the piping so arranged that any condensate trapped

in the pipework will drain away from the valve.

Note: It is recommended that the safety valve discharge pipework is installed to the requirements of

BS806 clause 4.9.7. / BSEN 134801-1:2002

(a) The lift pressure is indicated on the safety valve. (Do not adjust).

(b) Thesafetyvalvettedtotheboilerisdesignedtopreventtheboilerexceedingit'sdesign

pressure.

(c) Any system connected to the boiler not capable of accepting boiler pressure must be

protected by a separate safety valve set to the required pressure.

2.9 WATER GAUGE SET (The design may vary from that illustrated)

Numbers may vary due to individual countries regulations.

Boilers are normally supplied with two complete water gauge sets.The water gauge blowdown

cock should be connected to the auxiliary blowdown line from the water column blowdown valve in soft

copper tubing. The connection to the gauge cock is DN8, 6mm (1/4in. BSP).

2.10 GAS SUPPLy

Verify that the burner is suitable for the type of gas being supplied. Ensure 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 boiler. A scale trap is provided on the gas train and should be used.

Burners suitable for operation on natural and manufactured gas are supplied with gas trains or a

modulargasheadwhicharettedwithpressureregulatinggovernors.Aminimumpressureof7in.

(17.5mb)watercolumnatthespeciedowrate,isrequiredatthegastrainfornaturalgas

installationsandaminimumpressureof5in.(12.5mb)watercolumnisrequiredatthegastrainfor

manufactured gas installations.

If the gas supply is in excess of 100 mbar (6 - 30) or 200 mbar (40 - 60) a suitable regulator is required

before the main gas valve.

Burners arranged for operation on L.P. gas are supplied with gas trains which include a pressure

regulatinggovernor.ItisessentialthattheMAXIMUMpressureofthegasatthegastraindoesnot

exceed32in.(80mb)watercolumnanddoesnotfallbelow20in.(50mb)watercolumn.Toobtain

thesepressuresapressureregulatingdeviceorservicegovernormustbettedtothesupplyline

from the storage tank to the boiler gas train.

Careful consideration must be given to the siting of LPG storage tanks to prevent over pressure

conditions arising, due to temperature rises caused by solar gain.

2.10.1 GAS VALVE, with pilot gas line.

(Models 40 - 60 and Australian boilers).

Themaingasvalveisttedwithaby-passsystem(internalorexternaldependingonthemodel)

theby-passallowspilotpressuretobemaintanedwhilsttheameisveried.

2

WARNINGFactory tted safety valves are preset to protect the boiler only and

must not be used to protect an other items not capable of

accepting boiler pressure.

2

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12

FIG. 11 BURNER ELECTRODE SETTINGS

2.16 COMMISSIONING THE BOILER

It is essential that the commissioning procedures listed below are carried out by a Fulton Service

Engineer who will have the necessary experience and testing equipment to ensure that the installation

isnotonlycorrect,butisoperatingsafelyandatoptimumefciency.

FLUE COMMISSIONING

Priortoinitialringoftheboiler,theuemustbecheckedforleaks.

This is done by BOTH of the following methods:

Visual Inspection

Checkjointsbetweenalluesectionsforqualityofseals.Wheretheuepassesthroughthe

structureofthebuildinguseyourjudgementastotheintegrityofthissectionoftheue.

Smoe Test

Withtheuecapped,thedrainstabilizerpipe(iftted)blankedandasmokegenerator

insertedintotheue,thereshouldbenosmokevisiblefromtheue.If either of these tests fail or at any time during boiler operation, there is doubt about the integrity of the

ue,shutdowntheboilerandcontactFultonBoilerWorksImmediately.

Note: Flues that are designed to operate with positive pressure should be tested to the requirements

of IGE/UP/10 March 2001.

2.16.1 BOILER INSPECTION and INITIAL FIRING

(a) Ensure the boiler has been washed out after installation.

It is advisable to conduct a water analysis before operating the boiler.

Examine the probes in the water column and the boiler shell and record their lengths.

Replace any damaged probes.

(b) Iftheburneristtedwithanultravioletorsolidstatedetector,removethedetectorandcheck

for damage.

Remove the burner and check that the electrodes have not been damaged and that their

setting corresponds to the appropriate drawing.

(c) Check that the burner is the correct type for use with the gas being supplied.

2

Main Gas SupplyUltra-Violet Detector

Ignition Electrode

Primary Air

Blast Tube

3 mm min.

5mmmax.

297.4mm

12.7mm

50.8mm

2


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(d) Ensure that all wiring connections are correct and that all terminal screws are tight. (e) Abarometrictypedraughtstabiliser,ifttedintheue,shouldbesetforadraughtof-0.01in.

to

-0.02in.(-0.025mbto-0.05mb)ofwatercolumnpressurewiththeburneroff.

(f) Open all the valves in the feed water line.

Close the isolating valve on the discharge side of the feed water pump. Remove the priming plug

fromthepumpheadandslowlyllthepumpwithwater.Replacetheprimingplugandtightensecuerly.

Note the correct rotation of the pump on the motor fan cover.

Start the pump and check the direction of rotation.

Vent the pump by means of the vent valve in the pump head. At the same time, open the discharge

isolating valve a little. Continue to vent the pump. At the same time, open the discharge isolating

valve a little more. Close the vent valve when a steady stream of water runs out of it.

Completly open the discharge isolating valve.

Thebypassvalvelocatedinthedrainplugmaybeopenedduringthellingprocedure,closethe

bypass when the operation is stable.

DO NOT ALLOW THE PUMP TO RUN DRy.

2

FIG. 12 6 - 30J MODELS GAS VALVE

2

Main Gas Valve

Feed Water

Check Valve

Air Pressure Gauge

Safety Valve

Flue

13


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FIG. 14 40 - 60J MODELS GAS VALVE

Main Gas Valve Assembly

Main Gas Line Isolating

Pilot Line Ball Valve

Pilot Line Governor

Pilot Line Gas Valves Note:AustralianModelsaretted

with a Gas Valve Closed Indicator

on the Main Gas Valve

22

15


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(ii) Set the setback pressure control to therequired set back pressure.

2.16.2 SETTING THE BURNER CONTROLS FOR LOW FIRE / HIGH FIRE, MODELS 40 - 60

Thecorrectsettingforlowre/highreoperationaremadebymakingadjustmentsto thetwostage

solenoidvalveandthelowresteampressureswitch.

(a) Isolate the main gas valve by closing the valve in the gas input line.

(b) Screw the pilot gas governor fully down, (governor open).

(c) Start the burner and where possible meter the pilot gas rate, (ideally the pilot gas rate should be10% of the full gas rate).

(d) ChecktheLEDdisplayontheSatroniccontrolbox(wheretted). ThepilotshouldproduceasolidlineofveilluminatedLED's(fourminimum).

Check the ignition and pilot stability several times.

Record the pilot gas pressure.

(e) Open the main gas isolating valve.

(f) Setthegasinputtotheboilerforcorrectinputonhighre.Thisadjustmentshouldbedonewhere possible by using the gas meter.Adjust the main and secondary air gates to obtain optimum combustion conditions.

(g) Adjustthelowresteampressureswitchtocut-outatapproximately5psibelowthesettingofthe main steam pressure control.

(h) Adjustthetwo-stagesolenoidvalvetoobtainalowregasinputofapproximately80%ofhighre.

Leavetheairgatesadjustmentsasforhighre.

2 2

16


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2 2

2.17 GAS MULTIBLOCS (continued)

40 - 60 Models

(withpilotlinettedforAustralia)

Hydraulic Brake

Main Gas Flow Adjustment

High Fire Solenoid

Low Fire Flow

Adjustment

Test Point 1

Downstream

(internal leak test)

Test Point 2

Downstream

Test Point 1

UpstreamGas Input

Mounting Flange

Adjustable Pressure

Switch

Input Gas Test Point

Output Pressure Controller

Adjusting Screw

Operating Pressure Indicators

18


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OPERATION

3

SECTION 33.1 GENERAL

ThefollowinginstructionsaregivenfortheguidanceoftheoperatorintheuseoftheJSeriesgasred

boiler and to provide adequate information to ensure that when the boiler is put into use it will be done

safely and without risk to health. Where original equipment Service Manuals are supplied, they must

be read and understood in conjunction with this manual. All Warnings and Cautions must be observed.

DRyING OUT TIME

The refractory casing of the boiler is made from a material that uses a high proportion of water

in the mixing process. Whilst some of the water is driven off by chemical reaction and the

initialtestring,therefractoryisstill'wet'whentheboilerisdelivered.Forafewdaysaftertheboileris

commissioned and in service, water will be seen running from the bottom of the casing and from

around some branch pipes.

This is perfectl normal and part of the dring process.

3.2 BOILER CONTROLS

ThefollowingbriefdescriptionofthecontrolsusedontheJSeriesgasredboilerisintendedto

provide the operator with a basic understanding of the operating principles, which is essential for the

continuedefcientoperationoftheboiler.

Note:Allthecontrolsareofthefail-safetypeandarewiredinseries;failureofanyonewillautomatically

shutdowntheboiler.

Low Water Relas and Feedwater Pump Relas. These relays operate in conjunction with probes

suspended in the boiler and water column to automatically maintain the level of water in the boiler

and to cut-off the burner should the water level fall to an unsafe level.

Steam Pressure Control(s). Located on the control panel box and connected to the steam pressure

gauge assembly by copper tube, the pressure regulator controls the on/off cycle of the burner,

shutting the burner off when maximum pressure is reached and switching it on when the steam

pressure falls.

Note:Aset-backpressurecontrolleristtedwhenmulti-boilersarettedwithasequencecontrol.

Burner Programmer. This is the main control in the panel box. The programmer in conjunction with

asensingdevicesupervisestheignitionsequence,provestheameissatisfactoryandnally

monitorstheestablishedame.Shouldanyfaultoccur,eitherduringtheignitionsequenceor

during normal running, the programmer will immediately go to lockout and the multibloc gas valve

will be closed.

Air Pressure Switch. Mounted on the burner scroll, this switch is operated by the pressure of air enter-ingtheburnerthroughthethroatofthescroll.Lackofair,orinsufcientpressure,willpreventthe

switch completing the circuit thus preventing the burner from operating.

Gas Head Assembl. Consists of a multibloc incorporating an integral governor, pressure switch and

gas valves or for larger boilers in addition to the internal components, an external pilot line with

it's own gas proving valves and governor.

PUMP CONTROL

Pump Interrupt/Pump Run Switch.

Fitted on the left side of the control panel, used to override (switch off) the pump controls

during evaporation tests.

Australian Boilers onl.

Pilot Hold/Normal switch, Mounted on the right hand side of the boiler control box, the switch is used

toholdthemaingasvalveatpilotpressureinordertoverifythepilotame.

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3

FIG. 16 CONTROL PANEL FACIAS

6J - 30J Australia

40J - 60J Standard and Australian

(standard boilers have the CPI

indicator blanked)

6J - 30J

3

21

3.2 BOILER CONTROLS continued.

Note:

Boilersttedonskidunitsandinplantroomsareinterlockedwiththefeedwaterand

condensate return tank, after switching the boiler on at the boiler control box isolator switch,

the reset button on the tank control box must be reset.


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3.3 INDICATOR LIGHTS

Indicatorlightsarettedtothecontrolpanelasanadditionalaidtotheoperator.

The meaning and operating sequence of these lights is as follows:

CAUTION

The control circuit live light is dirived from a single phase. It is possible that with the control phasedown or a defective bulb the other phases could be live. Alwas isolate the suppl before investigat-

ing an fault.

Start/Low Water Reset. This switch is used to start the boiler and to reset the low water alarm. Whenthe switch is pressed to initiate the start-up sequence, the low water alarm lamp also illuminates andthe low water audible alarm sounds. Keeping the switch depressed for approximately 2 secondscancels the low water alarm and initiates the burner start sequence.Illumination of this switch and sounding of the audible alarm at any other time other than at switchon indicates that the boiler has gone to a lock-out due to a low water condition. Once the water inthe boiler has been restored to a safe operating level, pressing the switch will reset the controls.

Circuit On. (Circuit Energised 40J - 60J) Indicates that power is being supplied to the control panelbox.

Low Water Alarm (1st. low water). This light will energise, when the boiler is switched on and the

water level is between 1st. low water and 2nd. low water. A light will illuminate and a pulsing alarm

sound.

Low Water Reset (2nd low water). The 1st. low water light and alarm are replaced by the 2nd. low

water light and a continuous alarm, indicated by the low water reset switch. The second alarm must be

reset,therstalarmwillbeautomaticallyresetbythereturntonormalwaterlevel.

Ignition. Indicates that the ignition transformer has been energised. This light will only be illuminated

forapproximately5-10secondsduringtheignitionsequence.

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 adjusted after the boiler has been commissioned.

Start Gas. (40 - 60 models and Australian boilers)

This light indicates the gas valves in the pilot line are energised.

Main Gas. This light illuminates when the Multibloc gas valve is energised.

Flame Failure / Reset. This switch will be illuminated when the burner has gone to a lock out

conditionduetoamefailure.Theburnercontrollercanberesetbypressingthisswitch.

Combustion Air. This light indicates that the burner motor contactor is energised.

Closed Position Indicator (C.P.I.). (Australian Boilers Only)

The lamp illuminates when the gas valve is in the closed (no gas) position.

ADDITIONAL INDICATOR LIGHTS ON MODELS 40J AND 60J

Low Flame.

Thislightindicatesthattheburnerisoperatinginthelowamemode.

High Flame.

Thislightindicatesthattheburnerisoperatinginthefullringmode.

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3

3.5 STARTING THE BURNER

(a) CLOSE the main steam stop valve.

(b) Press the control switch to 'PUMP AND BOILER' position, the low water audible alarm willsound, the low water reset and low water alarm lights will illuminate.

(c) Press the low water reset switch for two seconds maximum.

The alarms will stop, and the alarm lights extinguish.

The burner start sequence will commence.

(d) Afteramaximumofoneminutetheburnershouldbering,andthemaingaslightON.

(e) When the boiler has achived the required (set) pressure, the main steam isolating valve

should be slowly opened allowing steam to enter the system distribution pipework.

WARNING

The sstem should be raised to temperature slowl to allowfor expansion and to avoid thermal shoc and water hammer.

This can be achived by one of two methods.

1. Crack open the main steam valve and allow the system to heat up slowly, (minimum

15minuets)beforefullyopeningthemainsteamvalve.

2. Open the main steam valve when starting the boiler, allowing the boiler and system to

heat up together.

Note: Thiscanleadtowaterloggingofthesteamlinesuntilfullpressureisachived.

Note: TDSPanelMountedControllers(BC3210-BC3200)iftted.

Thecontrollermustberesetafteranybreakinelectricalsupplytotheunit.

3.6 DAILy OPERATING TESTS (3.6 - 3.7)

Visuallyinspectthesteamandfeedwaterpipework,valvesandttingsforsignsofleakage.Ifleaks

are suspected shut the system down and evacuate the system to atmospheric pressure before

attempting to repair the leaks. The following procedure should be carried out by a competent person

to ensure the correct functioning of the water level and low water safety controls. Where possible, the

boilershouldnotbeundersteampressureduringthesetests,(see3.6.5.g.2.).

Note:Ensurethatthewaterlevelismaintainedduringthepressurebuildup.Ifanypartoftheequipment

isnotoperatingcorrectly,thefaultshouldbeinvestigatedbeforetheboilerisused.Ensurethatall

blowdownpipeworkissafeanddischargedtoablowdownreceptacle.

3.6.1. PUMP CHECk

Withtheburnerringandthepumpnotrunning,lowerthewaterlevelintheboilerbyopeningthe

main boiler blowdown valve.

As the water level falls, visible in the sight glass, and before the low water lock out position is reached

the water pump should start to run. When this happens close the main boiler blowdown valve.

Thewaterpumpshouldcontinuetorunandre-lltheboilertothecorrectlevelandstop.

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3

3.6.4 First Low Water Level

(a) Ensure the following:

Theburnerisring.The water level is correct in the boiler.

The water pump is not running.

(b) Switch the pump off (Pump Interrupt) at the pump interrupt/pump run switch.

(c) OPEN the main blowdown valve.

(d) When the water level nears the bottom of the water level gauge sight glass, the low water alarm

should sound, the LOW WATER ALARM lamp should illuminate and the burner should stop

ring.Whenthishappens,CLOSEtheblowdownvalveIMMEDIATELY.

(e) Switch the pump to RUN at the main pump interrupt/pump run switch. The pump should run

andrelltheboiler.Whenthewaterlevelintheboilerrisesabovetherstlowwaterlevel,the

LOW WATER LEVEL lamp should extinguish, the audible alarm should silence and the burner

start sequence should commence automatically.

The pump should run until the boiler water level is correct and then stop.

3.6.5 Overriding (2nd) Low Water Chec

(a) Ensure the following:

Theburnerisring.

The water level is correct in the boiler.

The water pump is not running.

(b) Switch the pump off (Pump Interrupt) at the pump intrrupt / pump run switch.

(c) OPEN the main blowdown valve.

(d) When the water level nears the bottom of the water level gauge sight glass, the LOW WATER

ALARM lamp should illuminate, the low water audible alarm should sound and the burner

shouldstopring.

(e) Continue to blow down the boiler. As the water level falls nearer the bottom of the water level

gauge sight glass, the LOW WATER RESET switch should illuminate and the second audible

low water alarm should sound.

(f) CLOSE the main blowdown valve and switch the pump to RUN at the pump interrupt/pump run switch.Thewaterpumpshouldnowstarttorunandrelltheboiler.Oncelledtothecorrect

level the pump should stop. The low water alarm should continue to sound, the LOW WATER

RESET switch and LOW WATER ALARM lamp should remain illuminated and the burner should

NOT start.

(g) When the water level in the boiler is correct, the burner can be restarted by depressing the

LOW WATER RESET switch for a maximum of 2 seconds.

1. The First and Overriding low water checks can be carried out in one operation to reduce

the blowdown time and possible interruption to the steam supply.

2. Where the water level tests are to be carried out at full pressure, evaporate the waterdown to 1st. low level as in 3.8, blowdown the boiler from 1st. to 2nd. low water.

The purpose of adopting this procedure is to prevent steam and water being expelled

from the blowdown vessel vent because of prolonged blowdown.

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3.7 BLOWDOWN PROCEDURES (DAILy TESTS)

Keep the boiler, water gauge, water column and interconnecting pipework free from sludge and scale

buildup by blowing down in the following manner:

Note: Where a boiler is operating continuously at steam pressure, advice should be sort from Fulton

regarding the appropriate blowdown procedure.

(a) Start the boiler and generate not more

than 10psi of steam.

(b) Shut off both the burner and the pump.

Boiler Blowdown

(a) Fully OPEN the boiler main blowdown

valve for not more than 10 seconds.

(b) CLOSE the valve.

Note: Where high levels of suspended solids are produced,

longer and/or more frequent blowdown may be required.

Water Column Blowdown

Note: The water column contains the pump

on/off probe, which is not safety interlocked.

(a) OPENtheballvalveinthewatercolumn,closeafter5seconds.

Australian Boilers onl

Water Column Blowdown

1. Place the sequence valve lever into the

blowdown column position A.

2. Open the Column blowdown valve B for

5secondsthenCLOSE.

3. Place the sequence valve lever into the

blowdown leg position C.

4. Open the Column blowdown valve B for

5secondsthenCLOSE.

5. Return the sequene lever to the working

26

A

B/DOWN COLUMN

D

WORkING

POSITION

C

B/DOWN LEG

B

A

C

D

Fig. 18 SEQUENCING BLOWDOWN VALVEFig. 17 BOILER BLOWDOWN VALVE

3 3

Water Column

Blowdown Valve

Operating handle shown

in the closed position.


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3.8 EVAPORATION CHECkS

With the boiler running under normal load conditions, and the pump stopped having just completed

arellcycle:

(a) Ensure that the boiler water level is correct.

(b) Switch the pump off at the pump interrupt / pump run switch.

The water level in the boiler will lower through natural evaporation. When the level nears the bottom of

thewaterlevelgaugesightglass,therstlowwateralarmwillsound,theLOWWATERALARMlamp

will illuminate and the burner will shut down.

If it is required to check the second low water alarm, wait a further period for the LOW WATER RESET

switch to illuminate.

When the check is complete, proceed as follows:

(a) Switch the pump to RUN at the pump interruptpump run switch.

(b) PresstheLOWWATERRESETswitch.Thepumpwillstarttorelltheboiler.

If the pump starts to run at any time during the test then the test must be abandoned and re-started

from the beginning.

27

Water Gauge Blowdown

(a) Blowdown the water gauge, set 1.

1. Open the gauge glass blowdown valve A

2. Close (for approx. 3 seconds) the top gauge valve B

3. Open valve B

4. Close (for approx. 3 seconds) the bottom gauge valve C5. 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 CLOSED.

Note: Where a Boiler is operating continuously at steam

pressure, advice should be taken from a Fulton agent

as to the appropriate blowdown procedure.

FIG. 19 WATER LEVEL GAUGES

WORkING

POSITION

STEAM

BLOWDOWN

WATER

BLOWDOWN

Water Level Gauge Operating Positions

A

C

Water Level Gauge

Set 2

B

A A A

B BB

C C C

3 3

Water Level

Gauge

Set 1


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3.9 TROUBLESHOOTING

Problem Cause Remed

Ignition Failure 1. Power Supply Check fuse or Circuit breaker.

Reset or Replace as required.

2. Ignition Electrodes Check for cracks in porcelain,if found replace the

electrode. Check electrodes for carbon build-up.

Clean as required.Check settings, adjust if

required.

3. Transformer Check voltage between transformer leads at

terminal block to be sure transformer is live.

4. Burner Control Check voltage between ignition terminal and

neutral, this check must be made before the

control locks out. If no power, replace the control.

5. AirSettings Checkmainairadjustmentandsecondaryair

adjustment.

6. Faulty Air Switch Check for faulty air switch. 7. GasValve Checkltersinthevalveblock.Cleanasrequired.

8. Gas supply Check for gas pressure and intermittent supply

problems.

9. Loose wire connections Check connections to all components.

Flame Failure 1. Power Supply Check fuse or Circuit breaker.

During Start-up 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. UVDetector Checkthedetectorislocatedcorrectlyandclean.

6. Burner Control Check voltage between ignition terminal and

neutral, this check must be made before the

control locks out.

If no power, replace the control.

7. Loose wire at

fuel valve circuit. Tighten wiring connections.

8. Contact open on

Air Switch Adjust to the correct setting.

9. UV Detector wiringreversed at control box. Change to the correct terminals.

Flame Failure 1. Power Supply Check fuse or circuit, reset or replace as

necesssary.

During Normal Run 2. Gas Supply Check gas pressure coming into the gas train,

if low contact the gas supplier.

Check the setting on the gas valve regulator,

adjust as required.

3. UV Detector Check the detector is located correctly and clean.

4. Faulty Air Switch Check for faulty air switch.

5. BadCombustion Checkcombustionreadings.

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3.9 TROUBLESHOOTING, continued.

Problem Cause Remed

Burner Cut-off 6. GasValve Checkltersinthevalveblock.Cleanasrequired.

7. WeakAmplier

(HoneywellControl Replacetheamplier.Box Only)

8. Weak Pilot Adjust to larger pilot by adjusting pilot gas

pressure regulator.

9. Faulty Level Control Test level controls, adjust or replace as required.

10. Dirty or defective

UV detector Clean or replace.

Poor Combustion1. Refractory Bricks Check refractories to see if they are plugged with

soot or broken in pieces. Clean or replace as

necessary.

2. StainlessSteelRing Checktheringispresent(40-60models)andts

tightly against the furnace wall.3. Main Air Adjustment Check air adjustment. Air/fuel mixture may be off.

Openmainairgateuntiltheamebrushesthe

furnace wall.

4. Secondary Air

Adjustment Check main air adjustment, reset as required and

secure in place. Check CO2

and O2

levels.

5. Draft Checkdraftwithagauge.Readingswillvary

between installations, if in doubt consult Fulton

for a draft value for your system.

6. DirtyFlue Checkueforcarbonbuild-uporblockage.

Cleantheue.

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 Bac Fires 1. Refractory Bricks Check refractories to see if they are plugged with

soot (Delayed Ignition) or broken in pieces.

Clean or replace as necessary.

2. 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.

3. UV Detector Check the detector is located correctly and clean.

4. Draft Check draft with a gauge.

Draftshouldbe-.05to-.10mbarwiththeburner off,

or-.10to-.15mbarwhenoperating.

A barometric damper may need to be installed.

5. NegativeRoomPressureEnsuretherearenoexhaustfansrunninginthe

boiler room.

6. Air Adjustment Check Air Adjustment settings.

7. Gas Supply Check gas pressure coming into the gas train,

if low contact the gas supplier.

Check the setting on the gas valve regulator,

adjust as required.

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Problem Cause Remed

Boiler will not

maintain pressure 1. Gas Supply Check gas pressure coming into the gas train,

if low contact the gas supplier.Check the setting on the gas valve regulator,

adjustasrequired.Ifpossiblemetertheowrate.

2. DirtyFlue Checkueforcarbonbuild-uporblockage.

Cleantheue.

3. Pressure Control Disconnect all power to the controller.

Disconnect the wires from the controller.

Place an OHM meter between the switch

terminals. Lower the set point of the controller,

the switch should make. Raise the set point and

recheck, the switch

should break. If the controller operates improperly,

replace it.4. Scale build-up in boiler Clean the pressure vessel. 5. RefractoryBricks. Checkrefractoriestoseeiftheyareblocked

with soot or broken in pieces. Clean or replace

as necessary.

6. Steam trapsblowing through. Check steam traps, clean or replace as required.

7. Boiler size. Boiler may be undersized.

8. FaultyGasValve. Checkgasowrate.

Boiler is Surging 1. Steam traps

(Widelyuctuating blowingthrough. Checksteamtraps,cleanorreplaceasrequired.water level in 2. Contamination Empty boiler and feed tank.

sightglass) inboiler. Flushoutandrell,ifsystemoperatesbutprogressively

deteriorates, there is probably a leak somewhere in thesystem.

3. Scale buildup orlime deposits. Consult Fulton or call a water treatment specialist.

4. Too much compound

(water treatment

overdose). Dumpcontentsofthereturntankandushthe

in the system. system. Test the water.

5. HighAlkalinity(highph). Haveawatertreatmentspecialisttestthewater.6. Load exceeds

boiler capacity. Check total system load against the output of the

boiler. Decrease the load required at any one time.

Boiler rumbles 1. Poor Combustion Check combustion readings.

and pulsates 2. Draft. Check draft with a gauge. Draftshouldbe-.05to-.1mbarwiththeburneroff.

A barometric damper may need to be installed.

3. Too much main air. Adjust main air gate.

Boiler carring over

water with 1. Steam Traps. Check steam traps, clean or replace as required.

the steam

2. Too much compound

(watertreatment Dumpcontentsofthereturntankandushthe

over dose) in the system. system. Test the water.

3. Contaminationinboiler. Emptyboilerandfeedtank.Flushoutandrell,ifsystem operates but progressively deteriorates,

there is probably a leak somewhere in the system.

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Problem Cause Remed

FEED WATER PUMP

Pump will not run 1. Supply failure. Connect the electricity supply.

2. Fuses are blown. Replace fuses.3. Motor contactor overload

has tripped out. Reactivate the motor protection.

4. Contactors

not making Check, the coil is faulty or wiring loose.

5. Controlcircuitisdefective. Repairthecontrolcircuit.6. Motor is defective. Replace the motor.

Motor starter

overload, trips out 1. One fuse/automatic circuit

immediatel when breaker is blown. Replace the fuse.

suppl is 2. Contacts in motor contactorswitched on. overload are faulty. Replace motor starter contacts.

3. Cable connection is

loose or faulty. Tighten or replace the cable connection.4. Motor winding is defective. Replace the motor.

5. Pumpblocked. Removetheblockage.

6. Overload setting too low. Set the motor starter correctly.

Motor contactor overload

trips out occasionall. 1. Overload setting is too low. Set the overload correctly.

2. Low voltage at peak times. Check the electricity supply.

Motor contactor has not Check :

tripped out but the Motor does not run when started:

pump does not run. items:1,2,4,5,6,

Pump capacit

not constant. 1. Pump inlet pressure is toolow (cavitation). Check the suction conditions.

2. Suction pipe/pump partly

blocked. Clean the pump or suction pipe.

3. Pump draws in air. Check the suction conditions.

Pump runs butgives no water. 1. Suction pipe/pump blocked. Clean the pump or suction pipe.

2. Foot or non-return valve

blocked in closed position. Repair the foot or non-return valve.

3. Leakage in suction pipe. Repair the suction pipe.

4. Air in suction pipe or pump. Check the suction conditions.

5. Pumprotatesinthewrong direction. Change the direction of rotation of

the motor.

6. Boiler feed water non-return Check and clean boiler feed water

valve letting water passed non-return valve, ensure it is seating

the valve seat, (normally and not allowing water passed.accompanied by banging in

the feed water tank).

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Feed Water Pump

Problem Cause Remed

Pump runs bacwardswhen switched off. 1. Leakage in suction pipe. Repair the suction pipe.

2. Foot or non-return valve is

defective. Repair the foot or non-return valve.

Leaage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal.

Noise. 1. Cavitation occurs in the pump. Check the suction conditions.

2. Pump does not rotate freely

(frictional resistance)

because of incorrect

pump shaft position. Adjust the pump shaft.

3. Frequency converteroperation. See Grundfoss manual.

4. Boiler feed water non-return Check and clean boiler feed water

valve letting water passed non-return valve, ensure it is seating

the valve seat, (normally and not allowing water passed.

accompanied by banging in

the feed water tank).

Water pump will not 1. Scale on probes. Check and clean probes, replace as

come on at times. 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 base. Replace if faulty.

Low fuel pressure. 1. Gas pressure regulator Check and replace.

Boiler ooding 1. Pump does not shut off. Dirty probes. Clean or replace as

necessary.

2. Relay failed. Ensure the relay is secure on its base.

If so replace the water level relay.

3. Earth connection. Clean and tighten as required.4. Vacuum created As the boiler cools, it pulls water from the

with boiler off. system piping. To prevent this, add a

check valve on the steam gauge

assembly piping, which closes under

pressure and opens under vacuum.

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3.10 TROUBLESHOOTING,

Burner Control Unit - LFL 1 (Landis and Staefa)

Smptom and Cause Remed

Identication Symbol

No Start 1. No Power Check all fuses.

Check for correct wiring.

2. External Interlocks Check all external interlocks are made.

3. Air Pressure Switch Check that the switch is in 'No Air' position.

4. CPIswitch Iftted,mustbemade.

5. AirDamper Iffullyclosingdampertted,check

relevant micro switch on damper.

6. Burner Moter fault Check overload.

Locout 1. Falseamedetected Checkforstraylight(cellonly).

Faultycellordamagedameprobe.

Interruption ofstart-up sequence 1. Air Damper Check fully open microswitch is made.

Locout 1. Air Pressure Switch Check that switch is made.

P 2. Note: An air pressurefailure after this time

will cause a locout

condition.

Locout 3. Flame supervision Check for stray light (cell only). Faultycellordamagedameprobe.

Interruption of

start-up sequence 1. AirDamper Checklowremicroswitchismade.

Locout 1. No ignition spark Check supply ignitor.

1 Check electrode and HT leadsfor damage.

2. Nopilotame Checkgassupply.

Check electrode setting.Check functionality of pilot gas valve(s).

Check pressure gas downstream of

pilot valve(s).

3. Pilot lights then

extinguishes Checkamestabilitywithignitionoff.

Note: Any ame signal Check air pressure at burner.

failure after this stage Check gas pressure is steady.

will cause a locout Checktheameisbeingsensed,i.e.

condition (i) Check sensor for damage.

(ii)Checksensorcanviewame.

(iii)Checkamesignal,

seedatasht.LFL1-7451

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3.10 TROUBLESHOOTING,

Burner Control Unit - LFL 1 (Landis and Staefa)

Smptom and Cause Remed

Identication Symbol

Locout 1. Nomainame Checksupplytomainvalve(s).

2 Check functionality of main valve(s).Check gas pressure at burner.

Check air pressure at burner.

Checkamesignalstrength,

refertoLFL1datasht.7451

Locout 1. Flamefailure Checkamesignal.

l 2. Air pressure failure Check switch operation.

Locout on completionof control programme 1. Extraneouslight Checkameextinguished.

sequence Check gas valves for leaks.

2. Faultyamesignal Checkforaged/faultyUVcell.

Checkamesupervisioncircuit.

34

3.11 TROUBLESHOOTING - Gas,

Burner Control Unit - TMG 740-3 (Satronic)

Routine Checs.

Testthesafetyoftheamedetectionsystemduring

commissioning and after servicing, or if the system

has not been in operation for a long period.

1. Bridge the gas proving switch.

2. Close the gas isolation valve.

3. Aftertherstsafetyintervalhaselapsed,

the boiler should lockout.

Test 1 Test 2

1. During normal boiler operation, remove the

amedetectorandblocklightfromthe

sensor. Lockout should occur within one

second.

Fault Finding

Faultndingisconsiderablysimpliedbymakinguseofthecolouredprogrammeindicator.Irregularities

during commissioning, normal operation or a normal shutdown pause can be localised via the programme

indicator disc. If malfunction occurs, it is useful to note the exact position of the indicator before operatingthecontrolswitchorresetbutton.Thefollowinglistisdesignedtoassistwithfaultnding.

COLOUR WHERE WHAT REASONBlue beginning does not start No power, break in control circuit, air proving switch not in

resting position.

continuousventilation Endswitch'MAX'airdamperdoesnotoperate.

line lockout Air proving switch does not switch over or is too late.

end continuous ventilation End switch 'ignition position' , air damper does not operate.anywhere lockout Stray light

yellow end lockout No ignition, no spark, no gas or too little gas

too much or too little air.

Flame detector selector switch set incorrectly.

Red end lockout Noamesignalcurrentortooweakafterendof

second safety interval (double fuel feed burner). Green end lockout Lossofameduringoperation,airpressuretoolow.

Blac end lockout Straylightduetoburningon,amedetectortubereached

endoflifeandactivatesshutoff,defectiname

detector circuit.

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3 3

3.12 DRAINING THE BOILER,

Boilers with manual blowdown valves

CAUTION

Your local regulations could state boiler water above 43OC must not be discharged into the drain.

ALWAYS check your local regulations.

1. Ensure the boiler is cold.

2. Isolate the boiler electrics at the isolator on the control box door.

3. Isolate the feed water tank and the feed water pump.

4. Open the main 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 sstems

1. The boiler should not be under pressure.

The boiler should be cold.

2. Close the blowdown isolation valve.

3. Using a screwdriver located as shown A, push up and make a quarter turn,

this will lock the button in position and open the blowdown valve.

4. Usingtheblowdownisolationvalvetothrottletheow,draintheboiler.

Note:Skidunitsandplantroomshaveinternaldrainagesystemswhichrequirethesameprocedures.

3.13 LONG TERM SHUT DOWN

To store the boiler in a corrosion-free situation there are three practical solutions:

1. Fullyoodtheboilertoexcludeasmuchairaspossible.

2. Drain the boiler completely.

Remove all hand hole and manhole doors.

Open all gas/oil side access doors.

3. As (2) but also introduce a form of convection heating to the gas/oil and water side.

A very effective solution is to install a string of outdoor type waterproof light bulbs distributedthroughout the boiler.

A


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3 3

MAINTENANCE LOG

Date Action Remars Sig.

This log should be completed regularly as a record of boiler maintenance.

36


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FIG. 20 BOILER MAINTENANCE

Handhole

Boiler Blowdown

Water Column

Blowdown

Water Level

Gauge Blowdown

Safety Valve

Outlet

Feed Water Pump

Interrupt Switch

4

37

Feed Water

Dip Pipe

Removing/replacing Water Level Probe

4


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FIG. 22 HANDHOLE

Crab

Gasket

4.4 MONTHLy (including weekly)

6. Inspect the hand holes in the boiler. If any leakage is evident proceed as follows:

Note: Use onl genuine Fulton replacement parts.

a). Using the special tee handle wrench, remove the handhole assembly.

b). Remove the old gasket and thoroughly clean the mating faces of the plate and boiler.

c). Fit the handhole assembly as follows:

1. Place the new gasket on the handhole plate and ensure that it is seating correctly.

Do not use any grease, lubricant or adhesive.

2. Position the plate in the boiler, set the crab and tighten the securing nut only

sufcientlytoprovideasnugt.Verifythepositionoftheplateintheboilerto

ensure that there is uniform space between the periphery of the door and the

boiler inspection opening. Tighten the nut hand tight only. Using the specialwrench, tighten the nut a further quarter of a turn. DO NOT OVERTIGHTEN.

d). If the gasket leaks as the pressure is building up, tighten the securing nut only

sufcienttostoptheleakage.

7. Inspecttheangedjointcoveringtherearinspectionportinwhichtheblowdownvalveistted,

if any leakage is evident replace the gasket.

8. Clean the sight glass. If any leakage is evident, renew the gasket.

Note: Isolate the gas supply.

9. Checkandcleantheultra-violetcell(iftted).

10. Checkfeedwaterandboilerwaterquality(seeWaterTreatrmentinsection5).

39

Handhole Cover

Plate

FIG. 21 REMOVING/REPLACING UVDETECTOR

4 4


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4.5 THREE MONTHLy (including monthly)

11. Drain and isolate the boiler.

12. Remove the lower handhole assemblies and inspect the interior of the pressure vessel forscale and sludge build up.

13. Remove the feedwater pipe from the top of the boiler. Ensure the pipe is not blocked,

clean as required.

Caution

Ensure the gas supply is isolated.

14. Disconnect the gas head from the burner by unscrewing the union.

Remove the burner plate screws, withdraw the burner assembly.

Clean the ignition electrodes and reset.

FIG. 25 BURNER PLATE

FIG. 23 BOILER FURNACE FIG. 24 IGNITION ELECTRODE

FIG. 26 BURNER ASSEMBLy(suitable lifting equipment must be used to lift any heavy items)

Lower refractory

brick in place

Insulating rope

4 4

40


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Cleaning

the Flues

Remove the cleanout door to

theuepassesandtothe

bottom of the boiler.Oil boiler illustrated.

Remove cover

plates and gasket

4.6 SIX MONTHLy (including three monthly)

It should be noted that after a Fulton boiler has been in operation for several months, pieces of burned metal

will be found in the space at the bottom of the boiler. These pieces of metal are the remains of a light gauge

metal form which was used during manufacture for the forming of the boiler insulation. This is normal and does

notaffecttheefciencyorthelifeoftheboilerinanyway.

15. Removethecoverplatesandclean-outdoor.Cleanouttheuepasses,checkthe

refractories for soot or breakage, inspect the stainless steel ring. When replacing the cover

plates and clean-out door, use new gasket material and furnace cement to ensure a tight seal,

thus preventing the escape of hot gases.

16. Apply a small quantity of oil to the bearings of the burner motor and the feed water pump motor.

17. Drainandushthefeedwatertank.Cleananyltersinthetank,inthefeedwaterlineorin


18. Remove and clean the water level probes, take care not to crack the porcelain. After

replacement of the probes, check the operation of the low water cutoff relay and of


19. Remove the air gate and clean the fan.

20. Testtheueusingthefollowingprocedure:

Visual Inspection

Checkjointsbetweenalluesectionsforqualityofseals.Wheretheuepassesthroughthe

structureofthebuildinguseyourjudgementastotheintegrityofthissectionoftheue.

Smoe Test

Withtheuecappedandasmokegeneratorinsertedintotheue,theirshouldbenosmoke

visible. If either of these tests fail, shut down the boiler and contact Fulton Boiler Works

immediately.

21. Remove the water gauge and water column. Rod through the top connections of both to

ensuretheholesinthebafeplates(approx..6mmdia.)insidetheboilerarenotobstructed.

22. Check the burner combustion to ensure that excess air and carbon monoxide values are within

normallimits(seecombustionvaluesinsection5).

23. Checktheconditionofthegasvalvelter(iftted),renewasrequired.

FIG. 27 FLUE CLEANING

4 4

41


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Appendix B

Motorised High/Low Control

1.1 Description

TheFultonmotorisedhigh/lowcontrolisdesignedtoimprovetheefciencyoftheboilerby

switchingtheringratefromhighre(whenthereislowsteampressureintheboiler)tolowre

(when the boiler reaches a high steam pressure).

The systems major components comprises; two stage gas valve, motorized air damper unit and

two stage steam pressure switch.

CAUTIONThe adjustment of the air gate control motor or the two stage

gas valve should only be carried out by qualied personnel,

incorrect adjustment could result in damage to the pressurevessel and/or the production of harmful combustion gases.

1.2 Operation

Withthesteampressureswitchpresettothehighandlowreoperationalrequirementsofthe 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

dampermotortothelowreposition.

Theboilerwillcontinuetooperateatlowreuntilthesteampressurefallstothelowpressurelimit

setting on the pressure switch, at this point, the gas valve and the air damper will switch the boiler

intohighremode,thesequenceofhighre/lowreisregulatedautomaticallywithnoroutine

maintenance required.

Note: Should the boiler attain the off setting of the on/off control pressure switch, the burner will switch

offonlowreandthenrestartinthenormalwayonhighre.

1.3 Additional Controls

Low Fire Hold Switch - Usedtomaintaintheboilerinthelowremodeduringcommissioning.

Air Damper Motor

High / Low Fire Cams

Air Damper Housing

B B

42


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2.2 Air Damper Motor - Factor Cam Settings (see 2.3 Setup procedure)

Terminal Position Degrees

N1 HighFireMotorCam 45O

N2 Low Fire Motor Cam 10O

N5 High Fire Interlock Cam 40O

N6 LowFireInterlockCam 15O

2 Commissioning

(commissioningshouldonlybecarriedoutbyaqualiedFultonServiceEngineer).

Toachievetheidealcombustionefciencyandgasinputrates,agasowratemeterisrequiredto

measure the fuel input to the boiler.

2.1 Fuel Input Rates

Model 6 8 10 15 20 30 40 50 60

Low Fire

m3/h 3.5 4.7 5.8 8.7 11.6 11.6 23.2 29.0 34.8

ft3/min. 2.1 2.8 3.4 5.1 6.9 10.3 13.7 17.1 20.5

High Fire

m3/h 7.0 9.3 11.6 17.4 23.2 34.8 46.4 58.1 69.6

ft3/min. 4.1 5.5 6.8 10.2 13.7 20.5 27.3 34.2 41.0

Note: Boilers are pre-commissioned before leaving the factory to ensure optimum gas input rates and com-bustion values.

Note: Thehighreinterlockcamshouldalwaysbesetapproximately5O

lowerthanthehighrecamposi-tion.Thelowreinterlockcamshouldalwaysbesetapproximately5Ohigherthanthelowrecamposition.

Motorised High/Low Control. continued.

Blue cam N7 not used

Red cam N6

Red cam N5

Red cam N4 not used

Red cam N3not used

Yellow cam N2

Yellow cam N1

B B

43


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2.3 Setup Procedure

1. Set the cams on the air damper motor to the initial position.

Starttheboilerandwaituntilthemotorandgasvalvehavedriventohighre.

Adjust the main (primary) air gate to achieve the best combustion with the least buffetingin the furnace.

2. Usingthelowreholdswitch,holdtheboilerinlowre.

Theairdampermotorshouldmovetoitslowrepositionandthehighrelightonthecontrol

panel extinguish, indicating the gas and air input rates have been reduced to approximately half

thehighreinputrate.

Note: Ifgasowrateequipmentisavailable,thelowregasinputrateshouldbeadjustedtothecorrect

value (see fuel input rates table) by rotating the black 1st stage partial adjustment ring located below the 2nd

stage solenoid.

3. TheideallowreCO2constituentoftheuegasesis8-10.5%.

Placeanexhaustgasanalyserintotheue,reduceorincreasetheamountofairenteringthe boilerasrequired,byadjustingthelowrecam(N2)position.

Note: The reaction of the motor to a change in cam positions is:

Reduced air: adjust the cam to reduce the amount of air entering the boiler, the reaction of the

motor will be immediate.

Increased air: adjustthecamtoincreasetheamountofairenteringtheboiler,switchthelowre

holdswitchoff.Whenthemotorhasdrivenbacktohighreturnthelowrehold

switchon,thedamperwilldrivebacktoitsnewlowreposition.

Adjust the cams until the correct CO2gureisachieved.Note: any adjustment to the cam positions requires an adjustment to its interlock cam position.

4. Switchoffthelowreholdswitch.

Note: ifgasowrateequipmentisavailable,thehighregasinputratecannowbeset(seefuelinputrates

table) by adjusting the pressure control screw located under a protective cover on the black electrical con-

nection block.

5. ThehighreCO2constituentoftheuegasesis10-10.5%.

Placeanexhaustgasanalyserintotheue,reduceorincreasetheamountofairenteringthe

boilerasrequired,byadjustingthehighrecam(N1)position.

Toreducetheamountofhighreair,thedamperwillhavetobedriventoitslowrepositionand

backagain,beforeittakesupitsnewposition.EnsurethatthehighreinterlockcamN5isalways

setapproximately5ObelowthehighremotorpositioncamN1.

Recordallcamsettingsandthehighandlowrenalgaselbowpressuresforfuturereference.

6. Adjust the pressure switch (PS2) to the high/low switch over point.


B B

44


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5.0 Spare Parts

Part No. Description Qt Model

10366 Casting,scroll 1 6-15 13195 Transformer,TRK2PCOFI 1 15

14437 Switch,airpressure,DL5A 1 15

14485 Motor,damper,A30045Y 1 15

14486 Inlet,scroll 1 15

14487 Fan,200x40x16 1 15

14489 Coupling,airgate 1 15

5-10-000480 Airgate,high/low 1 15

11327 Switch,lowrehold 1 15

14493 Valve,gas,MB-ZRD(LE)410B01 1 15


45

BB


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Spirax High Integrit Level Controls

ThedailytestingofboilerwaterlevelcontrolsisamandatoryrequirementasdenedintheHealth&Safety

ExecutiveGuidanceNotePM5.Thelevelofsupervisionisdependentuponthetypeoflevelcontrols(limiters)tted.

Boilersttedwithselfmonitoringhighintegritycontrols(limiters)shouldbetesteddailybyaqualiedboilerat-

tendant, but may be supervised during the silent hours and weekends by a Competent Person trained to re-

spond to an alarm.

Daily testing of the controls is required which can be by simulation, with a weekly test by interrupting the feed

water pump and lowering the water by evaporation.

Dail Test

1st. Low Water

1. Withtheburnerring

2. Pressandholdthe1st.LowWatertestbuttonuntil(minimum15seconds)thelowwateralarm

sounds, and the low water indicator lamp illuminates, and the burner shuts down

3. Release the test button

4. After approximately 17 seconds the low water alarm will cancel, the low water lamp will

extinguish, and the burner will restart

2nd. Low Water


2. Pressandholdthe2nd.LowWatertestbuttonuntil(minimum15seconds)thelowwateralarm

sounds, and the second low water reset switch illuminates, and the burner shuts down

3. Release the test button4. After approximately 17 seconds the second low water relay will reset.

5. To cancel the second low water level alarm and light, depress the second low water reset switch

6. The burner will restart.

C C

Appendix C

46

1st. LOW WATER 2nd. LOW WATER

HIGH INTEGRITY LEVEL LIMITERS

TEST:

with the boiler water at the normal working level,

press and hold each control for a minimum of

15 seconds, until the alarm sounds.

TESTTEST


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Weel Test (Daily test plus)

1st. Low Water

1.Withtheburnerring2. Switch the pump interrupt switch to the pump interrupt position.

3. Byevaporationlowerthewaterlevelintheboileruntiltherstlowwateralarmsounds

and the low water indicator lamp illuminates, and the burner shuts down

4. Switch the pump interrupt switch to the pump on position.

5. The pump will start and restore the water level to the normal position and switch off.

6. Afterapproximately17secondsfromrestoringtherstlowwaterlevelthelowwateralarmwill

cancel, the low water lamp will extinguish, and the burner will restart

2nd. Low Water


2. Switch the pump interrupt switch to the pump interrupt position

3. By evaporation lower the water level in the boiler until the low water alarm sounds, the second low

water reset switch illuminates, and the burner shuts down.

4. Switch the pump interrupt switch to the pump on position.

5. The pump will start and restore the water level to the normal position and switch off.

6. After approximately 17 seconds from restoring the second low water level the second low water

relay can be reset.

7. To cancel the second low water level alarm and light, depress the second low water reset switch

8. The burner will restart.

Note: These tests can be carried out consecutively, however it is possible that if the boiler is under load

conditionsthesecondlowwateralarmwilloccurimmediatelyaftertheburnerhasshutdownonrstlow

water, without the apparent loss of any more water. The reason is the collapse of the steam bubbles at the

water level surface when the heat is removed. The degree of collapse could be such that the water level willdisappear from the bottom of the site glass before the alarm sounds. Should this happen the second low

water level alarm should be checked by lowering the water level slowly by partially opening the main blow-

down valve.

Spirax High Integrit Level Controls, continued.

Pump Interrupt Switch

CC

47


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Systems that return for example very little condensate during the day, but a high proportion at night are almost

impossible to control with any real accuracy. At best a compromise calibration will be achieved, where too much

blowdown at times may be the penalty.

When installing and commissioning a new Automatic TDS Control Blowdown System, it must be accepted that

the calibration will be a reiterative process, requiring continual sampling, testing, and re-calibration until stable

system operating conditions are achieved.

When purchasing an Automatic TDS Control Blowdown Sstem from Fulton Boiler Wors (Great Britain)

Ltd, the equipment would normally be supplied with the controller wired and tted to the boiler control

panel, with all the other parts supplied loose for piping and wiring on site b others, unless agreed

otherwise in our order acnowledgement.

Thepurchasepriceofthesystemsuppliedfullyorpartttedincludesforonesinglevisittocommissionthe

system once installed. Part of the commissioning process will be the initial calibration of the TDS sensor to the

water conditions prevailing at the time.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

BoilerWorks(GreatBritain)Ltd.ifrequired.Inordertoachievethemaximumbenetfromtheinstallationofan

Automatic TDS Blowdown System, it is strongly recommended that site personnel be provided with the neces-

sary equipment, and training in order for them to fully understand the function of the system, and the possible

consequences of their actions.

Note:- Where Automatic TDS Blowdown systems are provided as part of a skid mounted or packaged plant

room unit, they will be fully installed piped and wired.

e.g. Hourly blowdown rate required to maintain a boiler TDS of 2000

with a feed water TDS of 200 = 12%

Fora1000kg/hboiler125kg/h(125l/h)ofblowdownisrequired.

DD

Automatic TDS Blowdown Sstems, continued.

49


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5

GENERAL DATA

SECTION 5

Standard Boiler Trim. Quantit

Main Steam Valve 1

Steam Safety Valve 1

Steam Pressure Gauge Assembly 1

Boiler Blowdown Valve 1

Water Level Gauge Set 1 or 2*

Feedwater Check Valve 1

Feedwater Stop Valve 1

Flue Spigot 1

Audible Alarm 1 or 2*

Flue Brush 1

Tee Handle Wrench 1

GAS COMBUSTION VALUES

CO2

range 9.5-10.5%

CO lessthan50ppm

O2 4.3-2.5%

Excess air 25-15%

Smoe -

Dimensions (mm)

Model 6J 8J 10J 15J 20J 30J 40J 50J 60J

A** 2300 2300 2300 2460 2600 2800 3100 3100 3100

B 1840 1840 1840 1990 2060 2240 2490 2490 2490

C 1060 1060 1060 1215 1285 1465 1710 1710 1710

D 1025 1025 1025 1175 1245 1385 1670 1670 1670 E 1670 1670 1670 1820 1890 2070 2320 2320 2320

F 1845 1845 1845 2010 2100 2310 2680 2680 2680

G1 2045 2045 2045 2225 2330 2510 2820 2820 2820

H 1500 1500 1500 1625 1670 1820 2075 2075 2075

J 1810 1810 1810 1960 2030 2210 2460 2460 2460

k 380 380 380 380 390 390 395 395 395

L 152 152 152 203 255 305 305 305 305

M 715 715 715 760 985 1175 1390 1390 1390

N 1025 1025 1025 1060 1400 1595 1850 1850 1850

P 265 265 265 265 265 265 265 265 265

Q 270 270 270 270 270 270 265 265 265

A

BC

D

SteamOutlet

H

Gas InletFeed Water Inlet

Flue Connection

EF

G1

Boiler

Blowdown

K

H

J

P

Q

L (dia)

360O

M

N

FIG. 28 BOILER DIMENSIONS

5

50


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5

51

6J 8J 10J 15J 20J 30J 40J 50J 60JOutput kg/h (F & A 100oC) 96 128 160 240 320 480 640 800 960

Std. working pressure. (bar). 10.34 10.34 10.34 10.34 10.34 10.34 10.34 10.34 10.34

Boilers at higher pressures are available as special orders

Firing Rates

Gas (m3/h) 7.09.311.6 17.4 23.2 34.8 46.4 58.1 69.6

Themainsgassupplypressuremustbebetween18.5mband50mb.

Electrical Requirements

FLC(400V,3ph,50Hz)amps 4.74.74.74.74.94.96.96.98.6

FLC(230V,1ph,50Hz)amps 12.7 12.7 12.7 12.7 14.9 - - - -

Water Content(litres) 91 91 91 205 291 640 1022 1022 1022

Weight dry(approx.kg) 810 810 810 1190 1420 2030 3150 3150 3150

Weight full(approx.kg) 900 900 900 1395 1711 2670 4172 4172 4172

Connection Sizes (DN) (F=female, M=male) (all connections BSP)

SteamOutlet 20F 20F 25F 32F 32F 40F 50F 50F 50F

FeedWater 15M 15M 15M 15M 15M 15M 15M 15M 15M

Safety Valve (discharge) 20F 20F 20F 20F 20F 20F 32F 32F 32F

Blowdown(Boiler) 20F 20F 20F 20F 25F 25F 25F 25F 25FBlowdown (Water column) 20F 20F 20F 20F 20F 20F 20F 20F 20F

Blowdown (Sight Glass) 8F 8F 8F 8F 8F 8F 8F 8F 8F

GasInlet 20F 20F 20F 32F 32F 32F 50F 50F 50F

Specication

issue1

5

Boiler Model 6J 8J 10J 15J 20J 30J 40J 50J 60JHigh Level (cm2) 305 360 420 560 700 980 1260 1540 1820

Low Level (cm2) 610 720 835 1115 1395 1960 2520 3085 3645

Ventilation - High and Low levels


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5 5

216

HighWaterProbe

216

241

405

430

PumpOff

PumpOn

1stLowWater

2ndLowWater

J SERIES BOILER PROBE LENGTHS

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

1st Low Water 405

2nd Low Water 430

Probe Lengths

Pump Off 216

Pump On 241

measurements in mm

Note: 350 Sight Glass

PROBE LENGTHS (TI65)

53


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5 5

FIG. 29 THREE PHASE SUPPLy CIRCUIT

54

1.

2.

3.

6.

5.

4.

L2 L3L1 N PE

PE

I NTER

LOCKEDDOORISOLATOR

BURNERM

OTOR

CT1

FEEDP

UMPMOTOR

CT1

BURNERMOTORC

ONTACT

OR

FEEDPUMP

MOTOR

CONTACTOR

BURNERM

OTOR

FEED

PUMPMOTOR

M3

~

M3

~

9.

8.

7.

OILPUMPMOTORCT1(IFFI TT

ED)

OILPUMPMOTOR

CONTACTOR(IFFI T

TED)

OILPUMPMOTOR

(IFFITTED)

M3

~

1:1TRANSFORM

ER

C CN

2AMCB

6J-60JSERIESP

ANEL

SUPPLYCIRC

UIT

( FOR

GAS,OIL&

DUALF

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