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`J` SERIES - OIL FIRED STEAM BOILERS (6J - 60J)

1. HION ANSSI SHONVHO S310N3G D NO r o x 2 5 GALLIS 41 NO 440 2 HalvM di ind HOIH gt 15 X zm I gt 2 R Q 5 5 H 2 m Lj A jm HI go zm gt 2 gt 27 gt 2 TE 2 69 C 2 x aL ZLLLOL 6 2111016 2 G 14S44 Hd LIVM PUZ 1 puz H zL o00 97 L HOLO314S HOLIMS FIG 24 SPIRAX LEVEL CONTROL CIRCUIT J OIL E 08 2008 45 110 SVD 404 LINDUID TANVd TONINOO 21 L 2000 90d94 18534 MOT Puc f NO HILVM HALVM NO 44O 841114 an 18 dnd HILVM 18 41 WYV1V 3 LVM 8 41 WH m 330 9 gt 8 dnd NOLLNA 14544 H019313S HOLIMS 46 J OIL E 08 2008 FIG 25 LC LEVEL CONTROL CIRCUIT 20009049 3 1314 110 Sv9 404 13NVd
2. lt 5 841114 aD 041114 40 FE og 49 131114 49 40 NNA XNVILOdWNd TIO XNVOdO 40 5 JOULNOO SQE cd 3oNano3s 8H svo 41 Q 4016 SLOWS EI n 841114 49 ONIHIA JHNSSIHA H9IH MO 66 eu aanva lt E Z H3IVM ve cH EE 0 Te H3IVM u Opi modd gt LMS rez ONILSIL 431108 SLOWSY o 9 41114 341 40 SNOLLO3NNOO 1 3138 941114 41 Svonio MNVL 1 Od MNVL ILVSNIGNOD YANSLIOS H31VM xnv xnvod PS WOINSHO NO xnv 1108 xnv 28 1 sl 841114 41 4 21 4018 40 OL 31034 2 FIG 23 ANCILLARY CONTROL CIRCUIT EJ06 0002 5 6J 60J SERIES PANEL FUSED TERMINAL ANCILLARY CONTROL CIRCUIT FOR GAS OIL amp DUAL FUEL BOILERS J OIL E 08 2008 44 M 2 1000 90398 SY31IOg 1and4 110 SVD LINOYIO T3NVd IONLNOD 5 OGY 0000908 53 681485 404 00009063 SONIMVHG OL 32338 NOILONYLSNI NOILVANILNOO HO4 NO
3. m m m NDR WO m m NS A A Control box assembly Control box assembly Switch isolator Contactor Cl Contactor n open Switch single pole Switch rocker Switch rocker Relay miniture Base miniture relay Contact aux Facia Relay LC3 Base relay Breaker circuit 3ph only Breaker circuit 1ph only Breaker circuit 1ph only Base burner control Switch handle Fuse Holder fuse Alarm audible Alarm audible Shaft extension Base Timer delay Control burner Control pressure Holder fuse Lamp indicator Lamp indicator Lamp indicator Cover pressure control top Transformer Fuse Lock and Key 400 3 50 240 1 50 25A 220 240V 11 pin 2 5 4 0 4 0 6 6 3 10 IP65 red 2A continuous pulsating 180mm 8 pin J OIL E 08 2008 December 2004 H1 1 1 PUMP FEED WATER December 2004 J OIL E 08 2008 Fulton H1 1 1 PUMP FEED WATER Item Part Number Qty Description Remarks Size 1 14284 1 Pump assy 3ph 125psi 8 6bar 6 15 14285 1 Pump assy 3ph 125psi 8 6bar 20 30 14285 1 Pump assy 3ph 150psi 10 34bar 6 20 14286 1 Pump assy 3ph 150psi 10 34bar 30 40 14288 1 Pump assy 3ph 150psi 10 34bar 50 60 14287 1 Pump assy 125psi 8 6bar 6 15 14289 1 Pump assy 125psi 8 6bar 20 30 14289 1 Pump assy 150psi 10 34bar 6 20 14296 1 Pump assy 150psi 10 34bar 30
4. J OIL E 08 2008 December 2004 Fulton D2 2 1 BURNER SCROLL ASSEMBLY OIL 20 30 December 2004 J OIL E 08 2008 mFulton D2 2 1 Part Number Qty BURNER SCROLL ASSEMBLY OIL 20 30 Description Remarks 020EO340 030EO340 10239 10242 10248 10269 10274 10275 10280 10282 10286 10367 10374 10578 10720 10755 10786 10793 10796 10810 10821 10831 10833 10841 10842 10849 10850 030EO460 10146 e b OO 4 BR BR OD B BR BP Aa A gt gt Scroll assembly Scroll assembly Transformer ignition Motor burner 550W Motor burner 550W Pump oil Fan burner Fan burner Coupling pump Coupling pump Valve solenoid Casting scroll Casting damper Nipple pipe Elbow Box conduit Bolt set Bolt set Bolt set Grubscrew Screw Washer Nut Washer Washer Washer Washer spring Gate air Insulation 2 P 240V 240 1 50 380 415 3 50 RSA 40 8 3 8in x 1 1 2in 9 15 16in x 1 1 2in 2 1 2in rubber DX 1 8in BSP 1 8in x 3in 75 75 37mm 6 x 16mm plated 8 x 20mm plated 8 x 30mm plated 1 2in x 1 4in 6 x 16mm Allen 1 4in x 3 4in M 8 plated M 6 plated M 8 plated M 6 plated M 8 plated 6mm glass yarn J OIL E 08 2008 December 2004 Fulton D2 3 1 BURNER SCROLL ASSEMBLY OIL 40 60 20 D2 3 1 Oil 40 60 12 2004 December 2004 J OIL E 08 2008 Ful
5. Operation J OIL E 08 2008 14 Fulton 3 2 16 2 17 COMMISSIONING THE BOILER continued n X Adjust the steam pressure control to suit the boiler application It should be borne in mind that boiler are designed to operate most efficiently at their maximum operating temperature When boilers are to be operated below a pressure of 80 psi 5 5 bar consideration should be given to the fitting of a pressure reducing set see Section 2 8 Steam Safety Valves If the pressure control is fitted with a differential scale see OEM literature in section 5 i Set the main scale pressure to the pressure indicated on the boiler data plate ii Set the differential scale to it s minimum pressure If the pressure control has a fixed differential e g no adjustable differential scale set the main scale to the maximum pressure required Note When boilers are fitted with a sequence control i Set the main scale and differential scale as above ii Set the set back pressure control to the required set back pressure FIG 12 PRESSURE CONTROLLER CLEANING STEAM LINES AND PRESSURE VESSELS During the first week of boiler operation clean all oil and dirt from the boiler the steam line and condensate return line a Disconnect the condensate return pipe adjacent to the condensate return tank b the returns to a floor drain or other safe discharge point and make safe c Leave in this position for one
6. continued Problem Boiler will not maintain pressure Cause 1 Oil tank empty Oil Nozzle Oil Valve 4 Oil Pump 5 Dirty Flue 6 Pressure Control N Scale buildup in boiler 8 Refractory Bricks 9 Steam Traps blowing through 10 Boiler size Remedy Refill the oil tank A slight delay in the re priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily Check for blocked nozzle Clean or replace Check voltage between oil valve leads at terminal block to be sure oil valve is getting power Check for blocked strainer or filter Remove and clean Check for slipping or broken coupling tighten or replace Check for seized pump shaft Replace the pump Check flue for Carbon build up or blockage Clean flue passages with brush 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 switch should break If the controller operates improperly replace it Consult Fulton Check the bricks are not plugged with soot cracked or broken into pieces Clean and replace as required Check traps clean or replace as required Boiler may be undersized J OIL E 08 2008 28 Fulton TROUBLESHOOTING continued Problem Boiler is Surging Boiler Rumbles
7. 40 14292 1 Pump assy 150psi 10 34bar 50 60 J OIL E 08 2008 December 2004 Material amp Workmanship Warranty On the Fulton Boiler Pressure Vessel Fulton Boiler Works Great Britain Ltd will repair or replace FoB factory any Fulton pressure vessel which within five 5 years of the date of delivery is found to be defective in workmanship or material provided this equipment is operated and maintained by the buyer for the purpose for which it was designed and in accordance with the Manufacturer s Handbook This Warranty does not cover damage or failures that can be attributed to corrosion scale or dirt accumulation or to low water conditions This Warranty is good only in the United Kingdom of Great Britain and Northern Ireland This Warranty does not include labour or delivery charges of any kind General Warranty The Fulton general Guarantee is given in lieu of and in exclusion of any warranty expressed or implied statutory or otherwise as to the state condition performance quality or fitness of the goods Save thereunder we shall be under no obligation or liability of any kind to you in regard to the goods In the case of new goods manufactured and supplied by us we will make good any defect developing therein under proper use within 12 months of delivery provided that after investigation in our sole discretion we are satisfied that the defect arose from faulty design materi
8. J OIL E 08 2008 4 HOL VHVd3s NMOGMO IH NODT NIVHG OL MOTA HAO S M I daAd ALTHOHLOV AAL VM IVOO HHL ANVIL V ALON ATddOS 11 HOCIU IO TVLAN TIO ANIT SAIYA HIA L HOVAGSSTIO OL 5 AAT WA INTIVTOSI HAHNIVALS HAL VM 000 Las NUNALAY ALY MINI THALS MNIT SSHINIVLS L NONWH TO AAT YA NMOGMO IH X IIOGH HATVA MOHHO VM dada wood 3202 SANTS AAT VA AAT WA INTIVTOSI SSV ID LHDIS G3LLI4 HAT VA TIvd HHS ITIAVLS LHOnVud ANIT NANLHA TIO THAHT HANUNA XAOSVSI YO MNVIIO 4I ANO ANIT TIO NI HATVANIMTOSI NZLIA NIVHGQ SNOINn MILLIA VHIVHAVS OL ANTVA AMLHAVS WWIIOH FHL DNIHAQHO NAHM 5 WILL AHTIOH CAVGNULS 5 14405 WVALS ANIT NMOGMOTA WNTOOD HAL FIG 3 TYPICAL INSTALLATION J OIL E 08 2008 Fulton 2 4 Note FLUE OUTLET The boiler is supplied with a stainless steel flue spigot that should 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 generally be subj
9. and ignition terminal and neutral Check must be made before the control locks out on safety If no power replace control Disconnect all power to the controller Disconnect the wires from the controller connect an ohmmeter between the switch terminals Lower the set pointof the controller the switch should make raise the set point and re check switch should break if the controller operates improperly replace it J OIL E 08 2008 26 Fulton Wi 3 11 TROUBLESHOOTING continued Problem Cause Remedy Poor Combustion 1 Refractory Bricks Check the bricks are not plugged with soot or broken into pieces Clean and replace as required 2 Stainless Steel Ring Check to ensure the ring is present and fits securely against the furnace wall 3 Main Air Adjustment Check air adjustment Open main air until fire brushes the furnace wall 4 Secondary Air Adjustment Check main air adjustment to see if it has moved Adjust as necessary and tighten in position Check CO and O level 5 Draft Check draft is neutral Consider installing a barometric damper if the draft is too strong 6 Dirty Flue Check flue for Carbon build up or blockage Clean flue passages with brush 7 Negative Room Pressure Ensure no exhaust fans are running in the boiler room 8 Oil Nozzle Check for blocked nozzle clean or replace as necessary 9 Oil Pump Check for blocked strainer or filter Remove or clean Check for slipping or broken coupli
10. are observed Thereafter inspections should be carried out at three monthly intervals A WARNING Prior to the commencement of any work requiring the removal of cover plates and the opening of the control panel box the electrical supply to the boiler must be isolated Feed Water Feed Water Non Steam Pressure Ball Valve return Valve Gauge Flame Detector Steam Supply Ignition Electrodes l a SEES Line Oil Feed Line Safety valve j Outlet Water Level Probes amp _ Water Column Level Probes oo old o ol B FIG 17 BOILER MAINTENANCE J OIL E 08 2008 32 Fulton 4 Wi The following procedures are designed to prevent the buildup of scale silt or sludge in the bottom of the boiler water gauge and water column pipework In addition to these procedures the advice of a water treatment specialist should be sought and followed Note for boilers fitted with Spirax High Integrity Level Controls see Appendix C 4 2 DAILY Some of the following procedures should be carried out as part of the normal operating routines of the boiler others are required to be done as part of the boiler maintenance programme All boiler operating routines and tests should be recorded and kept as a boiler history 1 Blowdown the Boiler 2 Blowdown the Water Column 3 Blowdown the Water Level Gauge 4 3 WEEKLY including daily A WARNING Ensure the fittings
11. furnace Refractory furnace Refractory furnace Refractory furnace Refractory furnace Remarks DN32 DN40 DN50 for TDS systems Bottom Top Top Top 10in 12in 140psi Birket 165psi Birkett 4in x 250psi Top Top Top Top Bottom Bottom Bottom Note To comply fully with safety regulations it is essential that the correct safety valves are used If in any doubt please contact Fulton Service Dept for assistance J OIL E 08 2008 December 2004 Fulton B2 1 1 BURNER ASSEMBLY OIL 6 15 B2 1 1 12 2004 December 2004 J OIL E 08 2008 Fulton B2 1 1 BURNER ASSEMBLY OIL 6 15 Item Part Number Qty Description Remarks Size 1 SA0032 1 Burner assembly 6 SA0033 1 Burner assembly 8 SA0034 1 Burner assembly 10 5 0035 1 Burner assembly 15 2 10285 1 Adaptor photocell 6 15 3 10290 1 Sensor flame 6 15 4 10595 1 Tube photocell adaptor 6 15 5 10729 1 Connector 16mm 6 15 6 SA0011 1 Lead ignition assembly 6 15 7 10249 2 Electrode angle Rajah 6 15 8 10321 2 Cable ignition 6 15 9 5 0028 1 Tube blast 6 15 10 10253 2 Electrode ignition 6 15 11 10255 1 Nozzle 1 65 g h 6 10256 1 Nozzle 2 g h 8 10257 1 Nozzle 2 25 g h 10 10258 1 Nozzle 3 5 g h 15 12 10265 1 Adaptor single nozzle 6 15 13 10318 1 Spring eye glass 6 15 14 10319 1 Glass eye Pyrex 6 15 15 10382 1 6 15 16 0022 1 Deflector 6 15 17 10580 1 Nipple pipe 6 15 18 107
12. Detector Loose wire connection Burner Control Oil nozzle clogging Faulty Oil Pump Power Supply Ignition Electrodes Main Air Adjustment UV Scanner Contact open on air safety switch Scanner wiring reversed at panel Oil Supply Oil Valve Oil Pump 10 Loss of Oil Prime Remedy Refill the oil tank A slight delay in the re priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily Check fuse or Circuit breaker Reset or replace as required Check electrodes for carbon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace Check voltage between transformer leads at terminal block to be sure transformer is live Check for ignition interference Check connections to all components Check voltage between pilot terminal and neutral and ignition terminal and neutral Check must be made before control locks out on safety If no power replace control Check oil nozzle s clean or replace as necessary Check to see if oil is being pumped to the boiler nozzle Repair or replace as necessary Check fuse or Circuit breaker Reset or replace as required Check electrodes for carbon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace Check air adjustment Air may be blowing flame away from the UV detector
13. OIL E 08 2008 December 2004 BURNER SCROLL ASSEMBLY OIL 6 15 D2 1 1 D2 1 1 Oil 6 15 12 2004 J OIL E 08 2008 December 2004 Fulton D2 1 1 BURNER SCROLL ASSEMBLY OIL 6 15 Item Part Number Qty Description Remarks Size 1 006EO340 1 Scroll assembly 6 8 010EO340 1 Scroll assembly 10 015EO340 1 Scroll assembly 15 2 10239 1 Transformer 2P 240V 6 15 3 10242 1 Motor burner 550W 240 1 50 6 15 10247 1 Motor burner 250W 2P 415 3 50 6 15 4 10269 1 Pump oil RSA 40 6 15 5 10271 1 Fan burner 6 1 4in x 1 1 2in 6 8 10272 1 Fan burner Tin x 1 1 2in 10 10274 1 Fan burner 8 3 8in x 1 1 2in 15 6 10280 1 Coupling pump 2 1 2in 6 15 7 10282 1 Coupling pump rubber DX 6 15 8 10286 2 Valve solenoid 1 8in BSP 6 15 9 10366 1 Casting scroll 6 15 10 10373 1 Casting damper 6 15 11 10578 A R Nipple pipe 1 8in x 3in 6 15 12 10720 1 Elbow 6 15 13 10755 1 Box conduit 75 75 x 37mm 6 15 14 10786 4 Bolt set 6 x 16mm plated 6 15 15 10793 4 Bolt set 8 x 20mm plated 6 15 16 10796 4 Bolt set 8 x 30mm plated 6 15 17 10810 6 Grubscrew 1 2in x 1 4in 6 15 18 10821 4 Screw 6 x 16mm Allen 6 15 19 10831 4 Washer 1 4in x 3 4in 6 15 20 10833 4 Nut M 8 plated 6 15 21 10841 6 Washer M 6 plated 6 15 22 10842 8 Washer M 6 plated 6 15 23 10849 6 Washer M 6 plated 6 15 24 10850 8 Washer spring M 8 plated 6 15 25 015 460 1 Gate air small 6 15 26 10146 1 Insulation 6mm glass yarn 6 15
14. Open primary air until fire brushes the furnace wall Check for dirt on scanner clean as required Check for proper location of detector Adjust to proper setting Change to correct terminals Check oil level in supply tank ensure it is not below _ intake line Fill tank with oil Check for clogged nozzle Clean or replace Check oil filter and replace if necessary Check the voltage between oil valve neutral at terminal block to be sure oil valve is getting power Check for clogged strainer or filter Remove and clean Check for slipping or broken coupling Tighten or replace Check for seized pump shaft Replace Check all lines for possible air leak in intake line and tighten Check the intake line is not restricted replace Note One of the most common causes of flame failure is dirt sediment in the oil filter oil lines solenoid valves or nozzle caused by a new delivery of oil If the oil tank level is allowed to fall near to the bottom of the tank it is highly probable that sediment on the bottom of the tank will be disturbed and mixed in with the new oil delivery especially if the delivery rate is too fast 25 J OIL E 08 2008 Fulton 3 TROUBLESHOOTING continued Problem Boiler Fails to Start Burner Cut off Cause 1 No Power 2 Pressure Control 1 Oil tank empty 2 Power Supply 3 Ignition Electrodes 4 UV Detector 5 Faulty Air Switch 6 Faulty Level Control N Oil No
15. Repeat for gauge set 2 Water Level Gauge q m G a Water Level Gauge operating positions F03200 Nb EVAPORATION CHECKS Fig 15 WATER LEVEL SIGHT GAUGE BLOWDOWN 3 8 With the boiler running under normal load conditions and the pump stopped having just completed a refill cycle 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 the water level gauge sight glass the first low water alarm will sound the low water alarm lamp will illuminate and the burner will shut down If itis 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 ON at the pump interrupt pump run switch b 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 23 J OIL E 08 2008 3 9 DRAINING THE BOILER Boilers with manual blowdown valves CAUTION Your local regulations could state boiler water above 43 C must not be discharged into the drain 5 6 ALWAYS check your local regulations Ensure the boiler is cold Isolate the boiler
16. Sequencing Valve 7 Boiler Top Components 8 Steam Pressure Gauge 9 Nozzle and Ignition Assembly 10 Commissioning the Boiler 11 Pressure Controller 12 Operator Control Panels 13 Sequencing Blowdown Valve 14 Water Level Sight Gauge Blowdown 15 Fault Finding Check List 16 Maintenance 17 Handhole 18 Burner Assembly 19 Flue Cleaning 20 Boiler Dimensions 21 Boiler Supply Circuit 22 Ancillary Control Circuit 23 Spirax level Control Circuit 24 LC Level Control Circuit 25 TDS and Blowdown Control Circuit 26 6J 30J Burner Control Circuit 27 40J 60J Burner Control Circuit 28 SPARE PARTS Boiler GA 2 1 Boiler Shell and Fittings 6 15 1 1 1 Boiler Shell and Fittings 1 2 1 Burner Assembly 6 15 B2 1 1 Burner Assembly 20 30 B2 2 1 Burner Assembly 40 60 B2 3 2 Burner Scroll 6 15 D2 1 1 Burner Scroll 20 30 D2 2 1 Burner Scroll 40 60 D2 3 1 Burner Scroll Dual Fuel 40 60 D2 5 1 Water Column E1 6 1 Water Level Gauge Assembly 300mm 6 60 F1 3 1 Water Level Gauge Assembly 350mm 6 60 F1 4 1 Control Box Assembly Dual Fuel 40 60 G1 10 1 Control Box Assembly 6 15 G2 1 1 Control Box Assembly 20 30 G2 2 1 Control Box Assembly 40 60 G2 3 1 Feed Water Pump H1 1 1 J OIL E 08 2008 Air Intake Manifold Feed Water to Boiler Steam Supply Valve Oil Pump Water Oil Column Strainer Probes Water Column Oil Feed Return Lines Boiler Control Panel Cleanout Door Handhole flue passes and Pressure Vessel flame turn around I
17. around the steam safety valve s are secure The safety valve will be very hot do not operate the safety valve without protection 4 Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe blowdown point 5 The water level and safety cut off controls must be tested under operating conditions by interrupting the water feed supply To carry out this test use the feed pump interrupt switch to isolate the feed water pump and lower the water level in the boiler by evaporation Lower the water level passed both the 1st and 2nd low water levels see section 3 On completion switch off pump run the pump interrupt switch and check that the water level is restored to normal 33 J OIL E 08 2008 4 4 MONTHLY including weekly 6 A WARNING Ensure the main electrical supply is isolated before starting work Inspect the hand holes in the boiler If any leakage is evident proceed as follows Note Use only genuine Fulton replacement parts 4 5 10 11 12 13 14 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 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 suffi
18. electrics at the isolator on the control box door Isolate the feed water tank and the feed water pump Open the main steam valve and the boiler drain valve Open the drain valve on the blowdown vessel Open all valves in the drain lines Boilers with automatic blowdown systems 1 4 The boiler should not be under pressure The boiler should be cold Close the blowdown isolation valve 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 Using the blowdown isolation valve to throttle the flow drain the boiler Note Skid units and plant rooms have internal drainage systems which require the same procedures 3 10 LONG TERM SHUT DOWN To store the boiler in a corrosion free situation there are three practical solutions 1 2 Fully flood the boiler to exclude as much air as possible Drain the boiler completely Remove all hand hole and manhole doors Open all gas oil side access doors As 2 but also introduce a form of convection heating to the gas oil and water side Avery effective solution is to install a string of outdoor type waterproof light bulbs distributed throughout the boiler J OIL E 08 2008 24 3 11 TROUBLESHOOTING Problem Ignition Failure Flame Failure see note Cause 1 Oi Oil tank empty Power Supply Ignition Electrodes Transformer UV
19. the boiler and to reset the low water alarm When the switch is pressed to initiate the start up sequence the low water alarm lamp also illuminates and the low water audible alarm sounds Keeping the switch depressed for approximately 2 seconds cancels 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 switch on indicates that the boiler has gone to a lockout safe condition due to low water Once the water in the boiler has been restored to a safe operating level pressing the switch will reset the controls Circuit On Indicates that power is being supplied to the control panel 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 the first alarm will be automatically reset by the return to normal water level Ignition This lamp indicates the ignition transformer has been energised it will remain illuminated for 5 10 seconds approximately during the ignition sequence Burner On This lamp indicates that the burner is running and that the flame is being monitored by the burner p
20. the boiler exceeding it s design pressure c system connected to the boiler not capable of accepting boiler pressure must be protected by a separate safety valve set to the required pressure d Long radius fittings to be used with a minimumof diameters to the first fitting A WARNING Factory fitted safety valves are preset to protect the boiler only and must not be used to protect any other items not capable of accepting boiler pressure 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 6mm 0 25in OIL SUPPLY The positioning of the oil storage tank will be dependent on site conditions and local regulations The burner fuel pump is of the bypass type requiring the installation of feed and return lines between the oil storage tank and the boiler These lines should be in tubing of a minimum bore of 10 mm A fire valve stop valve and check valves should be inserted in the oil feed line To avoid blockages in the fuel pump and burner nozzle a metal cartridge oil filter should be fitted Fibrous cartridge filters are not recommended The final connections between the fuel pump and the feed and return lines should be ma
21. the manifold FIG 10 NOZZLE AND IGNITION ASSEMBLIES J OIL E 08 2008 12 Wi Fulton 2 Feed Water Oil Supply Pipes Line Main Steam Valve Main Air Intake N Oil Strainer Boiler Data Plate 34 ater Leve 2 Sight Gauges 1 gt p Oil Flow Sight Gauge Return Blowdown Pipes Valves Water Column A 1 Engineers Test Blowdown 5 Valve Control Box i Isolator Switch Cleanout Door Cleanout Handhole FIG 11 COMMISSIONING THE BOILER 13 J OIL E 08 2008 Fulton 2 2 16 COMMISSIONING THE BOILER continued A barometric type draught stabiliser if fitted in the flue should be set for a draught of 0 01in to 0 02 0 025mb to 0 050 mb of water column pressure with the burner off Open all the valves in the water feed line Open all the valves in the feed water line FEED PUMP Close the isolating valve on the discharge side of the pump Remove the priming plug from the pump head and slowly fill the pump with water Replace the priming plug and tighten secuerly See the correct rotation of the pump on the motor fan cover Start the pump and check the direc tion 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
22. to ensure the material pressure vessel does not suffer from brittle fracture hydraulic testing should not be carried out below 5 C WARNING The importance of correct boiler water and feed water cannot be over emphasised see the relevant section in this manual A CAUTION LOW FEED WATER TEMPERATURE Low feed water temperature can resultin 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 CAUTION Obey all laws and local regulations which affect you and your boiler NWARNING Only qualified persons should be allowed to operate and maintain the boiler and its equipment Boilers should always be drained through an approved Blowdown Vessel NWARNING Do not change the boiler fuel without consulting the boiler manufacturer Z WARNING Non approved modifications can cause injury and damage Contact your Fulton dealer before modifying the boiler AN WARNING LIFTING EQUIPMENT Make sure that lifting tackle complies with all local regulations and is suitable for the job You can be injured if you use faulty lifting equipment Make sure the lifting equipment is in good condition N WARNING Operating the boiler beyond its design limits can dam age 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 modifications AN WARNING DA
23. when a steady stream of water runs out of it Completely open the discharge isolating valve The bypass valve located in the drain plug may be opened during the filling procedure close the bypass when the operation is stable DO NOT ALLOW THE PUMP TO RUN DRY Open all the valves in the water feed line Switch on the feed water pump motor and fill the boiler 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 sight level gauge is reading two thirds full the pump will stop Open the boiler blowdown valve and slowly drain the boiler When the water level falls below the PUMP ON probe the pump should start If the pump does not start check the probe connec tions Close the boiler blowdown valve Close the boiler blowdown valve Start the burner as detailed in Section 3 Operation Allow time for the fuel pump to prime itself After the burner has been firing for approximately five minutes adjust the main air control gate to obtain a clean combustion Observe the flame through the peephole between the electrodes and adjust the primary air control so that the flame cannot be seen backing up the blast tube Adjust the air main control to obtain a full swirling flame shape brushing the wall of the furnace by observing the flame through the eye glass in the burner plate Check the operation of the low water safety controls as detailed in Section 3
24. 1031409 SAL IWNINHIL QISNA NO NO ZL SAL Alddns H3TIOHLNOO AAWA anv WHVIV HOLIMS GION31OS N3dO Qqaso1o SaL SaL Od m JI Od 41 ge 41 000118 81 JOHINOD TOHLNOD 6L Od Q3N33HOS pony HI 99 99 FIG 26 TDS and BLOWDOWN CONTROL CIRCUIT J OIL E 08 2008 47 AINO S H3TIO8 110 404 aadav HOLIMS SH 6 ANSSI LIMJHID IOHLNOD iN O SEM L9 WHEL PUE SEM 2 INSSI TANVd 59145 9 OL 43444 NOILONYLSNI NOLLVANILNOO HO4 7 2000 90ra 41 N N JHASSIHA HOSN3S SSH SWV14 Gace 841114 41 Sd tas 841114 41 431114 41 va JHNSSIAHA NOVA 135 431114 41 8H OLNV TIVANVA 41 He HOLIMS ZZ SSOJNVG 041114 an IVANVW OLAV 14S34 JHASSIAHA 9 u 9 XVHIdS l 1 9 XVUIdS ISL JO 9 G IM1 01 99 FIG 27 6J 30 BURNER CONTROL CIRCUIT Oil Boilers only 48 J OIL E 08 2008 MN AINO 5 110 404 LINOYIO TOHLNOD HINUNA 8000 90f 3 TANVd 531435 roo ror N N JHASSAHA Q31114 i 69 HOH SOSNSS NOLL
25. 16 1 Elbow 1 8in BSP x 1 4in 6 15 19 10785 6 Bolt 1 4in x 3 4in UNC 6 15 20 10786 2 Bolt 6 x 16mm plated 6 15 21 10800 1 Nut M10 plated 6 15 22 10810 2 Grubscrew 1 2in x 1 4in 6 15 23 10832 6 Nut 1 4in UNC plated 6 15 24 10838 1 Nut domed 10mm plated 6 15 25 10839 1 Lever air damper 6 15 26 10977 2 Washer eye glass 6 15 27 11033 8 Washer flat 1 4in plated 6 15 28 11139 8 Washer spring 1 4in plated 6 15 29 050 430 1 Plate burner 6 15 30 050 470 1 Holder electrode 6 15 31 SA0005 1 Gate air 6 15 32 10793 4 Bolt 6 15 33 10850 4 Washer spring 6 15 34 10842 4 Washer 6 15 35 11130 1 Ring combustion stainless steel 6 15 J OIL E 08 2008 December 2004 Fulton B2 2 1 BURNER ASSEMBLY OIL 20 30 B2 2 1 Oil 20 30 10 2008 December 2004 J OIL E 08 2008 mFulton B2 2 1 BURNER ASSEMBLY OIL 20 30 Item Part Number Qty Description Remarks Size 1 SA0036 1 Burner assembly complete 20 SA0037 1 Burner assembly complete 30 2 10285 1 Adaptor photocell 20 30 3 10290 1 Sensor flame 20 30 4 10595 1 Tube photocell adaptor 20 30 5 10729 1 Connector 16mm 20 30 6 SA0011 1 Lead ignition assembly 20 30 7 10249 2 Electrode angle Rajah 20 30 8 10321 1 Cable ignition 20 30 9 020 30 1 Burner assembly 20 030EO330 1 Burner assembly 30 10 SA2209 1 Tube blast was 10127 20 30 11 10144 Rope insulation 20 30 12 1025
26. 3 2 Electrode ignition 20 30 13 10259 1 Nozzle 5 g h 20 10262 1 Nozzle 7 g h 30 14 10256 1 Adaptor single nozzle 20 30 15 10318 1 Spring eye glass 20 30 16 10319 1 Glass eye Pyrex 20 30 17 10325 7 Clip 1 2in 20 30 18 10383 1 Plate top 20 30 19 SA0023 1 Deflector was 10396 20 30 20 10581 1 Nipple pipe 1 8in x 12in 20 30 21 10716 1 Elbow 20 30 22 10785 6 Bolt 1 4in x 3 4in UNC 20 30 23 10786 2 Bolt 6 x 16mm plated 20 30 24 10800 1 Nut M10 plated 20 30 25 SA0005 1 Gate air 20 30 26 10810 2 Grubscrew 1 2in x 1 4in 20 30 27 10832 6 Nut 1 4in UNC 20 30 28 10838 1 Nut domed 10mm plated 20 30 29 10839 1 Lever air damper 20 30 30 10849 2 Washer spring 20 30 31 10977 2 Washer eye glass 20 30 32 11033 8 Washer flat 20 30 33 11139 6 Washer spring 20 30 34 050E0430 1 Plate burner 20 30 35 050 470 1 Holder electrode 20 30 36 10796 5 Bolt 20 30 37 10850 5 Washer spring 20 30 38 10842 5 Washer 20 30 39 11131 1 Ring combustion 20 30 J OIL E 08 2008 December 2004 Fulton B2 3 2 BURNER ASSEMBLY OIL 40 60 B2 3 2 Oil 40 60 12 2004 December 2004 J OIL E 08 2008 Fulton B2 3 2 BURNER ASSEMBLY OIL 40 60 Item Part Number Qty Description Remarks Size 1 SA0041 1 Burner assembly complete 40 SA0042 1 Burner assembly complete 50 SA0043 1 Burner assembly complete 60 2 10289 1 Sensor flame
27. 4 0 6 3A 6 15 18 11942 1 Breaker circuit 3ph only 1 6 2 5A 6 15 11962 1 Breaker circuit 1ph only 6 3 10A 6 15 19 11950 1 Plate control base front 6 15 20 12016 1 Handle switch IP65 red 6 15 21 12854 4 Fuse 3ph only 2A 6 15 22 12855 4 Holder fuse 3ph only 6 15 23 13380 1 Alarm audible continuous 6 15 24 13381 1 Alarm audible pulsating 6 15 25 13560 1 Shaft extension 180mm 6 15 26 14215 1 Control pressure 4 12bar 6 15 27 14330 3 Holder fuse 6 15 28 14332 1 Lamp indicator red 6 15 29 14333 4 Lamp indicator amber 6 15 30 14334 1 Lamp indicator green 6 15 31 14335 1 Cover pressure control top 6 15 32 14367 1 Transformer 250VA 6 15 33 14368 3 Fuse 1A cartridge 6 15 34 12545 1 Lock and Key 6 15 J OIL E 08 2008 December 2004 Fulton G2 2 1 CONTROL BOX ASSEMBLY OIL 20 30 ase Ur m am T el E 21 em 1 December 2004 J OIL E 08 2008 Fulton Part Number G2 2 1 Description Remarks CONTROL BOX ASSEMBLY OIL 20 30 020EO324UK 020EO322UK 10448 10496 10507 11327 11526 11587 11596 11597 11667 11793 11829 11831 11869 11904 11942 12019 11943 11962 11950 12016 12854 12855 13380 13381 13560 14215 14330 14332 14333 14334 14335 14367 14368 12545 0 0 4 0 wo 3
28. 40 60 3 SA0012 1 Lead ignition assembly 40 60 4 10249 2 Electrode angle Rajah 40 60 5 10321 A R Cable ignition 40 60 6 040EO331 1 Burner assembly 40 050EO331 1 Burner assembly 50 060EO331 1 Burner assembly 60 7 10128 1 Tube blast 40 60 8 10140 A R Rope insulation 12mm 40 60 9 10253 2 Electrode ignition 40 60 10 10259 A R Nozzle 5 g h 40 50 10262 A R Nozzle 7 g h 50 60 11 10318 1 Spring eye glass 40 60 12 10319 1 Glass eye Pyrex 40 60 13 10325 9 Clip 1 2in 40 60 14 10327 1 Spinner 40 60 15 10350 2 Nipple pressure test 40 60 16 10384 1 Plate top 40 60 17 10397 1 Deflector 40 60 18 10402 1 Control damper 40 60 19 10581 1 Nipple pipe 1 8in x 12in 40 60 20 10595 1 Nipple pipe 3 4in x Sin 40 60 21 10627 1 Bush lin x 3 4in 40 60 22 10716 2 Elbow 40 60 23 10785 6 Bolt 1 4in x 3 4in UNC 40 60 24 10786 2 Bolt 6 x 16mm plated 40 60 25 10796 6 Bolt 8 x 30mm plated 40 60 26 10810 2 Grubscrew 1 2in x 1 4in 40 60 27 10832 7 Nut 40 60 28 10842 6 Washer flat 40 60 29 10850 6 Washer spring 40 60 30 10977 2 Washer eye glass 40 60 31 11033 9 Washer flat 40 60 32 5 0008 1 Gate air 40 60 33 11139 8 Washer spring 1 4in plated 40 60 34 12758 1 Nipple pipe 1 8in x 14in 40 60 35 13504 1 Manifold double nozzle 40 60 36 050EO430 1 Plate burner 40 60 37 050EO470 1 Holder electrode 40 60 38 11133 1 Ring combustion 40 60 J
29. 5mm 40 60 34 10687 1 Box junction 40 60 J OIL E 08 2008 December 2004 M WATER COLUMN 6 60 E1 6 1 00006 XX KW ON XX NOS 1 6 1 12 2004 J OIL E 08 2008 December 2004 Fulton E1 6 1 WATER COLUMN 6 60 Item Part Number Qty Description Remarks Size 1 SA2250 1 Bottle water assembly 6 60 2 10418 1 Probe pump off 180mm 6 60 3 10592 1 Nipple 3 4in 6 60 4 10598 3 Nipple 6 60 5 10627 1 6 60 6 10670 2 Union 6 60 7 10696 1 Tee 6 60 8 11524 1 Valve ball DN20 6 60 9 11541 1 Probe pump on 8 1 2in 6 60 10 14067 1 Casting bottle 6 60 11 099E9370 1 Basket water bottle 6 60 J OIL E 08 2008 December 2004 Fulton F1 4 1 WATER LEVEL GAUGE ASSEMBLY 6 60 350mm and 300mm Clifton December 2004 J OIL E 08 2008 mFulton F1 4 1 WATER LEVEL GAUGE ASSEMBLY 6 60 350mm and 300mm Clifton Item Part Number Qty Description Remarks Size 1 12444 A R Gauge water level assy 350mm centres 6 60 12207 A R Gauge water level assy 300mm centres 6 60 2 12199 2 Valve 300 amp 350 6 60 3 12210 1 Valve blowdown 300 amp 350 6 60 4 10621 1 Bush 300 amp 350 6 60 5 11895 1 Glass 350 6 60 12200 1 Glass 300 6 60 6 11893 2 Gasket 350 6 60 12201 2 Gasket 300 6 60 7 12208 10 Bolt 300 amp 350 6 60 8 10850 10 Wa
30. 6 3 2 BOILER CONTROLS continued Fuel Pump Mounted on the burner scroll and driven by the burner motor the fuel pump delivers oil to the burner nozzles at the correct pressure to allow complete atomisation and therefore combustion 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 BOILER CONTROLS Note Boilers fitted on skid units and in plant rooms are interlocked with the feed water and 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 Fulton n L I START PUMP ONIX FLAME FAILURE LOW WA TER CIRCUIT BURNE R IGNITION OIL OIL OFF OFF ALARM ON ON VALVE VALVE L W RESET PUMP amp BOILER ALARM 6 307 oil START PUMP ONLY FLAME FAILURE LOW LOW WA TER CIRCUIT BURNE R IGNITION FLAME MAIN O O O ALARM ON ON START FLAME L W RESET PUMP amp BOILER RESE T 4 oil FIG 13 CONTROL PANELS J OIL E 08 2008 Fulton 3 3 3 INDICATOR LIGHTS Indicator lights are fitted to the control panel as an additional aid to the operator The meaning and operating sequence of these lights is as follows Start Low Water Reset This switch is used to start
31. Boiler pushing water with steam Pump will not cutoff Pump runs but does not put water in the boiler Water pump runs intermittently Boiler contiues after shut down Oil fumes coming out around the oil pump housing on shut down Boiler flooding Cause Qo Steam Traps blowing through Scale buildup or lime deposits Too much water treatment Too much of a load Draft Problem Too much main air Air or water in the oil Steam Traps Too much water treatment Dirty Probes Relay failed Earth connection Vapour locking of pump Blocked feed water line Scale on probes Bad pump contactor Pump Motor damaged Oil Valve defective Bad draft condition Venting of room Pump does not shut off Relay failed Earth connection Vacuum created with the boiler off Remedy Check traps clean or replace as required Call water treatment company and consult the factory Dump the return tank and flush the system Test the water treatment Check total equipment load against the boiler output Decrease amount of equipment being used Check draft is neutral Consider installing a barometric damper if the draft is too strong Adjust main air Check tank and lines for water or leaks Check traps Clean or replace as required Dump the return tank and flush the system Test the water treatment Clean or replace as required Check r
32. Fult Fulton Boiler Works Great Britain Ltd INSTALLATION OPERATION MAINTENANCE AND PARTS MANUAL SERIES OIL FIRED STEAM BOILERS 6 60J This Manual must be available to the boiler operator at all times J OIL E 10 2008 Fulton Wi A 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 any 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 supply to the boiler should be isolated immediately until such time that the fault has been investigated by a competent person and rectified Z WARNING Steam Boilers are a potential hazard possibly fatal if not properly maintained It is vitally important that the instructions given in this manual are strictly adhered to Failure to carry out the routine maintenance checks could result in a drastic reduction in the life expectancy of the boiler Continual improvement in boiler design and fittings may result in some of the components used being different to those in this manual if in any doubt about individual components or their operation contact Fulton Service Department NOTE The Pressure System Safety Regulations 2000 Fulton Boilers fall within the scope of the Pressure Systems Examination Scheme
33. INDI di efl Q3LL14 t 1 7 554 41 e E 141114 3n 1 4D JHNSSIHA LSd vH MOV 135 vSd 1 vH MVANVA I qaia 3n HOLIMS L 8 1 226 MXC 5 i l aatia JIE AL 13544 JHASSIAHd 149 XVHIdS 149 XVUIdS ISL JO i V G LM1 91 FIG 28 40 60J BURNER CONTROL CIRCUIT Oil Boilers only J OIL E 08 2008 49 Fulton 6 SPARE PARTS SECTION 6 In order to ensure spare parts are correct please complete the details below and have them at hand when ordering parts or making enquires regarding the boiler Boiler number Boiler type Type of fuel used Wiring Diagram No Commissioning Date OV The type size and lift pressure of the safety valve fitted to a boiler is specific to that boiler When ordering new safety valves it is important that as well as the information requested above the following additional information is given Boiler design pressure located on the boiler data plate Make and type e g fig no of safety valve fitted J OIL E 08 2008 50 0 2 1 BOILER OIL 2 J December 12 2004 J OIL E 08 2008 Fulton 0 2 1 BOILER OIL Item Part Number Qty Description Rem
34. NGER FROM HOT SURFACES Steam Boilers have high temperature surfaces that if touched may cause serious burns Only competent and qualified personnel should work on or in the local ity of a steam boiler and ancillary equipment Always ensure the working area and floor are clear of potential hazards work slowly and methodically Z WARNING DANGER FROM INCOMPLETE COMBUSTION The importance of correct burner adjustmentto achieve low emissions safe clean and efficient combustion is paramount Poor combustion where unburnt oil forms carbon monoxide is both a health hazard and the potential risk to the boiler from overheating caused by re burning of the unburnt gas in the secondary flue passes CAUTION WATER 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 plant operate without chemicals or the wrong dosage of chemicals J OIL E 08 2008 Fulton Optional Variations where fitted Appendix Spirax High Integrity Level Controls LIST OF ILLUSTRATIONS TITLE FIG NO Oil Fired Steam Boiler 1 Boiler Top View 2 Typical Installation 3 Boiler Flue Connection 4 Boiler Feedwater Arrangements 5 Boiler Blowdown 20 60 6 Boiler Blowdown 6 15 6A Water Column
35. Oil Pressure psig 127 153 Capacities and Weight Water Content litre Weight Empty kg Weight Operating kg Electrical Requirements FLC Amp 400V 3ph 50Hz 240V 1ph 50Hz Oil Boiler Combustion Values CO range 11 5 12 5 co less than 100ppm O range 5 4 Excess air 30 20 Smoke 3 max 41 J OIL E 08 2008 Fulton 5 IMPORTANT Recommended Water Conditions It is very important that a strict water management program is followed to ensure trouble free boiler operation The following are recommended for feedwater and boiler water FEEDWATER water entering boiler pH Value Hardness Suspended Solids Chloride Organic Matter Oil 8 5 to 9 5 tested at room temperature less than 2 0 mg kg in the form of None Less than 50 mg kg Less than 5 mg kg None BOILER WATER water inside boiler pH Value Hardness Suspended Solids Chloride Oxygen Scavenger Sodium Sulphite or Tannin Phosphate Total Alkalinity Caustic Alkalinity Total Dissolved Solids TDS Iron Silica Dissolved Oxygen mg kg Caco PO SiO 1 Grain hardness therefore 7 For practical purposes mg kg 9 5 11 5 tested at room temperature Not detectable Less than 100 mg kg Less than 500 mg kg 20 to 50mg kg Less than 50 mg kg in the form of PO Less than 1000 mg kg Less than 300 mg kg as CaCO Less than 2000 ppm Less than 1 mg kg Less than 150 mg kg in the form of
36. Refractory furnace Top 15 9 12040 1 Refractory furnace Bottom 6 15 10 10006 1 Door cleanout 6 15 11 10009 1 Handhole assembly Top 6 8 10010 1 Handhole assembly Top 10 10011 1 Handhole assembly Top 15 13764 2 Handhole assembly Bottom 6 15 12 10017 A R Gasket handhole 6 15 13 10023 1 Wrench tee Handhole 6 15 14 11524 1 Valve blowdown 6 15 15 14257 1 Valve feed water stop 6 15 16 5 0002 1 Valve check assembly 6 15 17 11824 2 Gasket 6 15 18 14126 1 Valve check 6 15 19 11825 2 Flange 6 15 20 10119 1 Flue flange 6 10 10120 1 Flue flange 15 21 10417 1 Probe water level 6 15 11882 1 Probe water level 6 8 11774 1 Probe water level 10 15 22 099E9360 2 Basket probe 6 15 23 10558 2 Valve steam safety 3 4in Bir 130psi 6 15 11504 1 Valve steam safety 3 4in N V 130psi 6 15 11609 2 Valve steam safety 3 4in Bir 125psi 6 15 11952 1 Valve steam safety 3 4in Bir 140psi 6 15 11953 1 Valve steam safety 3 4in Bir 165psi 6 15 24 10135 A R Gasket flue cover 6 15 25 10022 1 Brush flue 6 15 26 13508 1 Connector flue male 6 10 13510 1 Connector flue male 15 13509 1 Connector flue female 6 10 13511 1 Connector flue female 8in 15 27 13568 3 Clip flue connector 6 15 28 SA0045 1 Pipe feed water dip 6 15 SA0046 1 Pipe feed water dip for TDS systems 6 15 Note To comply fully with safety regulations it is essential that the correct safety valves are used If in any doubt please conta
37. 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 SAFed SAFETY ASSESSMENT FEDERATION Limited Nutmeg House 60 Gainsford Street Butlers Wharf London SE1 2NY b Health and Safety Executive local office c Your Competent Person J OIL E 08 2008 Fulton LIST OF CONTENTS TITLE SECTION INTRODUCTION 1 General 1 1 Technical Data 1 2 INSTALLATION 2 General 2 1 Siting 2 2 Ventilation 2 3 Flue Outlet 2 4 Water Supply 2 5 Blowdown Valves 2 6 Main Steam Valve 2 7 Steam Safety Valve 2 8 Water Level Gauge Set 2 9 Oil Supply 2 10 Electrical Requirements 2 11 Steam Pressure Gauge 2 12 Commissioning the Boiler 2 16 Cleaning Steam Lines and Pressure Vessels 2 17 OPERATION 3 General 3 1 Boiler Controls 3 2 Control Panel Indicator Lights 3 3 Filling the Boiler All Models 3 4 Starting the Burner All Models 3 5 Daily Operating Tests 3 6 Pump Check 3 6 1 First Low Water Level Check 3 6 4 Overriding Low Water Check 3 6 5 Blowdown Procedure
38. SiO None Milligrams per Kilogram Calcium Carbonate Phosphate Silica 17 118 ppm 4 10 grains hardness ppm It is critical that the boiler water pH be alkaline 9 5 11 5 whenever water is in the boiler Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids TDS Consult your Water Treatment specialist to establish the frequency and duration of blowdown required to achieve the required water conditions J OIL E 08 2008 42 M 000 9073 43109 1314 110 Sv9 304 531035 09 9 041114 41 YOLOW 110 ONIMVY OL 434344 NOILONYLSNI NOLLVANILNOS 03 HOLOW 0334 ALON HOLOW 431114 4 HOLOVLNOO MOLOVINOO HOLON YOLOW dWNAd 10 9933 YOLOVLNOS HOLOW DDD DDD X 83 14 41 119 110 LLO LLO HOLOW HaNUNA b Tues Y Y Y Tor 3SVHd 3 TONIS T GON Ve MERE X N H e HOW vz GOW H 21 2 x X HIWNHOAJSNVAL HOLVIOSI 4008 Q3390 TH3 NI FIG 22 BOILER SUPPLY CIRCUIT J OIL E 08 2008 43 Fulton
39. Water Column Australian boilers only 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 7 WATER COLUMN SEQUENCING and BLOWDOWN VALVES Australian boilers only J OIL E 08 2008 2 Fulton 2 Oil Supply Flame Detector Ignition i Location Electrical Transformer Connection Box 2 Oil Supply Adjustable M DES 7 Air Control Oil Pump Ignition Secondary Air Electrodes Damper Flame Detector Safety Valve Burner Assembly Oil Supply Steam Supply Connections Pipe Water Level Probes Ignition Electrodes FIG 8 BOILER TOP COMPONENTS 9 J OIL E 08 2008 Fulton 2 2 7 2 8 Note 2 9 2 10 2 11 MAIN STEAM VALVE The main steam stop valve should be inserted in the steam line approximately 12in 305 mm from the top of the boiler STEAM SAFETY VALVES Safety Valves are factory fitted and preset they MUST NOT be adjusted The discharge outlet 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 It is recommended that the safety valve discharge pipework is installed to the requirements of BS806 clause 4 9 7 a lift pressure is indicated on the safety valve Do not adjust b safety valve fitted to the boiler is designed to prevent
40. a YD Control box assembly Control box assembly Switch isolator Contactor Cl Contactor n open Switch single pole Switch rocker Switch rocker Relay miniture Base miniture relay Lamp indicator Facia Base burner control Control burner Relay LC3 Base relay Breaker circuit 3ph only Breaker circuit 1ph only Breaker circuit 3ph only Breaker circuit 1ph only Plate control base front Switch handle Fuse 2A Holder fuse Alarm audible Alarm audible Shaft extension Control pressure Holder fuse Lamp indicator Lamp indicator Lamp indicator Cover pressure control top Transformer Fuse Lock and Key 400 3 50 240 1 50 25A 220 240V 3ph only Amber Black 4 pole 4 pole red 11 pin 1 6 2 5A 4 0 6 2 5 4 0 6 3 10 IP65 red 3ph only 3ph only continuous pulsating 180mm 4 12bar red amber green 250VA 1A J OIL E 08 2008 December 2004 Fulton G2 3 1 CONTROL BOX ASSEMBLY OIL 40 60 December 2004 J OIL E 08 2008 Fulton Part Number G2 3 1 Description Remarks CONTROL BOX ASSEMBLY OIL 40 60 050E0324UK 050E0322UK 10448 10496 10507 11327 11527 11587 11596 11597 11737 11794 11869 11904 11943 12019 11962 11971 12016 12854 12855 13380 13381 13560 13650 13717 13889 14215 14330 14332 14333 14334 14335 14381 14438 12545 WO m JA A m
41. als or workmanship and from no other cause whatsoever Defective goods or parts must be returned to us as soon as possible after discovery of the defect Costs of carriage and of detaching and incorporating parts will be borne 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 Fulton Boiler Works Great Britain Ltd Broomhill Road Bristol BS4 4TU England Telephone 0117 972 3322 Fax 0117 972 3358 mail uk info fulton com web site www fulton com
42. arks Size 1 1 Boiler shell and fittings See A1 1 1 6 15 1 Boiler shell and fittings See A1 2 1 20 60 1 Boiler shell and fittings See A2 1 1 Australian 6 15 1 Boiler shell and fittings See A2 2 1 Australian 20 60 2 1 Burner assembly See B2 1 1 6 15 1 Burner assembly See B2 2 1 20 30 1 Burner assembly See B2 3 2 40 60 3 1 Burner scroll assembly See D2 1 1 6 15 1 Burner scroll assembly See D2 2 1 20 30 1 Burner scroll assembly See D2 3 1 40 60 4 1 Column water assembly See E1 3 1 Australian 6 60 1 Column water assembly See E1 6 1 6 60 Gauge water level See F1 4 1 6 60 1 Box electrical control See G2 1 1 6 15 1 Box electrical control See G2 2 1 20 30 1 Box electrical control See G2 3 1 40 60 not illustrated 1 Pump feed water See H1 1 1 6 60 J OIL E 08 2008 December 12 2004 Fulton A1 1 1 BOILER SHELL AND FITTINGS 6 15 UK and Australia A1 1 1 6 15 oil December 2004 J OIL E 08 2008 Fulton A1 1 1 BOILER SHELL AND FITTINGS 6 15 UK and Australia Item Part Number Qty Description Remarks Size 1 10535 1 Valve steam stop DN20 6 8 10536 1 Valve steam stop DN25 10 10537 1 Valve steam stop DN32 15 2 10566 1 Gauge pressure 4in x 250psi 6 15 3 5 0001 1 Gauge pressure assy 6 15 4 10565 2 Tee 6 15 5 10548 1 Valve 6 15 6 10655 1 Plug 6 15 7 10564 1 Syphon pigtail 6 15 8 10001 1 Refractory furnace Top 6 10 12037 1
43. ating principles which is essential for the continued efficient operation of the boiler A WARNING The control circuit live light is derived from a single phase It is possible that with the control phase down or a defective bulb the other phase could be live Always Isolate the supply before investigating any fault Note All the controls are of the fail safe type and are wired in series failure of any one will automatically shut down the boiler Low Water Safety Relays and Feed Water Pump relays 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 Burner Programmer This is the main control in the panel box The programmer in conjunction with a sensing device supervises the ignition sequence proves the flame is satisfactory and finally monitors the established flame Should any fault occur either during the ignition sequence or during normal running the programmer will immediately go to lockout and the burner will shut down J OIL E 08 2008 1
44. ciently to provide a snug fit Verify the position of the plate in the boiler to 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 special wrench tighten the nut a further quarter of a turn DO NOT OVER TIGHTEN d If the gasket leaks as the pressure is building up tighten the securing nut only sufficient to stop the leakage Inspect the flanged joint covering the rear inspection port in which the blowdown valve is fitted if any leakage is evident replace the gasket Clean the sight glass If any leakage is evident renew the gasket Clean any strainers in the feed water line Check and clean the UV detector Clean any water traps and strainers fitted in the fuel line Check the operation of any steam traps fitted on the condensate return system Check boiler and feedwater quality see water treatment in section 5 Remove clean and adjust the oil nozzle and electrode assembly THREE MONTHLY including monthly 15 16 17 Drain and isolate the boiler Remove the lower handhole assemblies and inspect the interior of the pressure vessel for scale and sludge build up Remove the feedwater pipe from the top of the boiler Ensure the pipe is not blocked clean as required J OIL E 08 2008 34 gt AB Handhole Cover Plate Gasket FG00180 FIG 18 HANDHOLE Ignition nd Transforrner Ignition Leads Burn
45. ct Fulton Service Dept for assistance J OIL E 08 2008 December 2004 Fulton A1 2 1 BOILER SHELL AND FITTINGS 20 60 UK and Australia A1 2 1 20 60 June 07 December 2004 J OIL E 08 2008 Fulton UK and Australia 1 2 1 BOILER SHELL AND FITTINGS 20 60 Item NOOR WD O 28 Part Number 10537 10538 10539 SA0044 11825 11824 14126 14257 SA0045 SA0046 13732 10006 13764 10012 10013 10014 10017 10018 11525 13512 13514 13568 13544 13545 13546 10136 10023 11952 11953 SA2200 10417 11774 SA0001 10565 10655 10548 10564 10566 10002 12038 12149 12039 12041 12148 10003 Qty PUDE AAN SD ANNA A KA Description Valve steam stop Valve steam stop Valve steam stop Valve check assembly Flange Gasket Valve check Valve feed water stop Pipe feed water dip Pipe feed water dip Brush flue Door cleanout Handhole assembly Handhole assembly Handhole assembly Handhole assembly Gasket handhole Gasket handhole Valve blowdown Connector flue Connector flue Clip connector Plate flue cover Plate flue cover Plate flue cover Gasket flue cover plate Wrench tee Valve steam safety 3 4in Valve steam safety 3 4in Basket probe Probe water level Probe water level Gauge pressure assy Tee Plug Valve Syphon pigtail Gauge pressure Refractory furnace Refractory furnace Refractory
46. de with the flexible fuel lines supplied If the oil storage tank is positioned higher than the boiler a non return valve should be fitted to the return line To overcome suction problems at the fuel pump all vertical lifts in the feed pipe should be made as close to the boiler as possible The burner fuel pump pressure is preset at the factory and should not require adjustment ELECTRICAL REQUIREMENTS An individual wiring diagram for the boiler is located on the inside cover of the control box When referring to the electrical specification of the boiler the reference number located on the rear inside wall of the control box and the wiring diagram number should be quoted The audible alarms provided are mounted on the side of the control panel if not audible they should be repositioned where they can be heard by a person competent to take 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 feed water pump motors arranged for operation on a three phase supply The power ratings and requirements are given in Technical Data Section 5 J OIL E 08 2008 10 Steam Pressure Gauge Plug Steam Cock Test Point q END F03210 FIG 9 STEAM PRESSURE GAUGE 2 12 STEAM PRESSURE GAUGE The steam pressure gauge assembly should be assembled in accordance with Fig 9 using a suitab
47. e low water reset switch for 2 seconds maximum The audible alarm will silence and the alarm lamps will extinguish The burner start sequence will commence d After a maximum of one minute the burner should be firing and the burner on lamp should illuminate 19 J OIL E 08 2008 3 3 5 3 6 Note STARTING THE BURNER continued e When the boiler has achieved the required set pressure the main steam isolating valve should be slowly opened allowing steam to enter the system distribution pipework A WARNING The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock and water hammer This can be achieved by one of two methods 1 Crack open the main steam valve and allow the system to heat up slowly minimum 15 minuets before fully opening the main steam valve 2 Open the main steam valve when starting the boiler allowing the boiler and system to heat up together Note This can lead to water logging of the steam lines until full pressure is achieved DAILY OPERATING TESTS 3 6 3 7 Visually inspect the steam and feed water pipework valves and fittings for signs of leakage If leaks 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 bo
48. ect to local planning regulations and approvals The following information is intended to provide assistance where the installation of a simple flue is required Where multi boiler flues or difficulties are experienced specialist advice should be obtained The flue diameter must be the same or larger than the flue flange provided with the boiler and the outlet should be at least 1 meter higher than the nearest ridge to avoid down draughts Where a chimney cowl is fitted care should be taken to ensure that the distance between the lowest point of the cowl and the top of the flue is 1 5 X the diameter of the flue and that it is of the terminal cone type FIG 4 BOILER FLUE CONNECTION 1 If the flue layout is such that it may produce an excessive up draught a draught stabiliser may be required 2 Avoid fitting 90 deg elbows whenever possible if unavoidable compensate by increasing the flue diameter 3 Ensure all flue pipes from the boiler to the main flue have a rising pitch J OIL E 08 2008 2 5 Note Note 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 commission
49. elay is secure on its base if so replace the relay Check for tightness and clean Allow system to cool down check steam traps and check to be sure return lines are not insulated Check return tank temperature if it is above 82 C vapour locking of the pump will occur Inspect check valves Clean and replace as needed Replace pump with multi stage centrifugal pump able to cope with 121 C Check feed water line is not blocked clean as required Check probes clean as required Check to ensure the contactor is live Check to ensure the contactor coil is being pulled in Replace as required Check the pump circuit is live If the circuit is live but the pump is not running replace the pump Check the valve is opening and closing Clean or replace as required Check the draft with a gauge should read neutral May need to install a barometric damper Ensure the boiler room doors are closed and the recommended vents are clear Dirty probes clean or replace as required Check relay is secure on its base if so replace the relay Check for tightness and clean As the boiler cools it pulls water from the system To prevent this add an anti vacuum valve on the steam gauge assembly piping this valve closes under pressure and opens under vacuum J OIL E 08 2008 Fulton 3 Supply Oil Supply Ignition Flame Burner Burner Boiler Boiler Failure Failure Cutoff Combustion Back will not will not Fires Ma
50. er Plate Screws Burner Burner Motor Scroll Photocell Air Gate XEN Electrodes Fan Oil Feed Pipe Air Damper Burner Plate Burner Top Plate Oil Line Spider Electrode Holder Coupling Deflector Plate Fuel Pump F00850 FIG 19 BURNER ASSEMBLY 35 J OIL E 08 2008 46 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 forming the boiler insulation This is normal and does not affect the efficiency or the life of the boiler in any way 18 19 20 21 22 23 Remove the cover plates and clean out door Clean out the flue passes Check the refractories for soot or breakage inspect the stainless steel ring When replacing the cover plates and clean out door use furnace cement to ensure a tight seal thus preventing the escape of hot gases Apply a small quantity of oil to the bearings of the burner motor and the feed water pump motor Drain and flush the feed water tank Clean any filters in the tank in the feed water line or in the feed water pump Remove and clean the water probes take care not to crack the porcelain After replacement of the probes check the operation of the low water cutoff relay and o
51. er level surface when the heat is removed The degree of collapse could be such that the water level will disappear 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 Pump Interrupt Switch 39 J OIL E 08 2008 Fulton 5 SECTION 5 GENERAL DATA 6 8J FIG 21 BOILER DIMENSIONS Dimensions mm A B D E G H J K L M N 2300 1840 1060 1025 1670 1845 1550 1500 1810 380 152 715 1025 265 270 J OIL E 08 2008 40 5 5 WARNING It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted to the boiler in a correct and safe manner Connection Sizes DN F female M male All connections BSP Steam Outlet Feed Water Safety Valve discharge Oil Pump inlet return Main Boiler Blowdown Water Column Blowdown Sight Glass Blowdown Flue Outlet dia mm Specification Model 6 8 Output kg h F amp A 100 C 96 128 Standard Working Pressure bar 10 34 Firing Rates Input KW h 75 100 Input BTU h x 1000 255 340 Input 35 sec oil US gal h 1 9 2 5 Input 35 sec oil litre h 7 0 9 4 Nozzle Size US gal h 1 65 2 0 Nozzle Spray Angle 809 S Oil Pressure barg 8 8 10 6
52. evel 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 water down to 151 low level as in 3 8 blowdown the boiler from 151 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 21 J OIL E 08 2008 Fulton 3 3 7 Note Note Note 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 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 5 seconds D CLOSE the valve Where high levels of suspended solids are produced longer and or more frequent blowdown may be required Water Column Blowdown The water column contains the pump ON OFF probe which is not safety locked a Switch the pump off at the pu
53. f the feed water pump Remove the air gate and clean the fan Test the flue using the following procedure Visual inspection Check joints between all flue sections for quality of seals Where the flue passes through the structure of the building use your judgement as to the integrity of this section of the flue Smoke test With the flue capped and a smoke generator inserted into the flue their should be no smoke visible If either of these tests fail shut down the boiler and contact Fulton Boiler Works immediately 24 26 Remove the water gauge and water column Rod through the top connections of both to ensure the holes in the baffle plates approx 6mm dia inside the boiler are not obstructed Check the burner combustion to ensure that excess air and carbon monoxide values are within normal limits see combustion values in section 5 Cleaning the Flues 10 Remove the cleanout door to the flue passes and to the bottom of the boiler FG00200 FIG 20 FLUE CLEANING J OIL E 08 2008 36 J OIL E 08 2008 Appendix C Spirax High Integrity Level Controls The daily testing of boiler water level controls is a mandatory requirement as defined in the Health amp Safety Executive Guidance Note 5 The level of supervision is dependent upon the type of level controls limiters fitted Boilers fitted with self monitoring high integrity controls limiters should be tested dail
54. he pump should run and refill the boiler When the water level in the boiler rises above the first low water level 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 J OIL E 08 2008 20 3 6 5 2nd Overriding Low Water Check for boilers fitted with Spirax High Integrity Level Controls see Appendix C a Ensure the following The burner is firing The water level is correct in the boiler The water pump is not running Switch the pump OFF at the pump override switch OPEN the main blowdown valve 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 should stop firing Continue to blow down 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 CLOSE the main blowdown valve and switch the pump ON at the pump override switch The water pump should now start to run and refill the boiler Once filled to the correct level the water pump should stop The low water alarm should continue to sound the LOW WATER RE SET switch and LOW WATER ALARM lamp should remain illuminated and the burner should NOT start When the water l
55. iler should not be under steam pressure during these tests see 3 6 5 g 2 Ensure that the water level is maintained during the pressure build up If any part of the equipment is not operating correctly the fault should be investigated before the boiler is used Ensure that all blowdown pipework is safe and discharged to a blowdown receptacle 3 6 1 3 6 4 Pump Check With the burner firing and the pump not running lower the water level in the boiler by opening the 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 The water pump should continue to run and re fill the boiler to the correct level and stop First Low Water Level for boilers fitted with Spirax High Integrity Level Controls see Appendix C a Ensure the following The burner is firing 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 firing When this happens CLOSE the blowdown valve IMMEDIATELY e Switch the pump to RUN at the main pump interrupt pump run switch T
56. ing the boiler see Section 5 Water Treatment Connect the feed water pump discharge to the check valve inlet with 25mm bore pipe this may be reduced to 15 mm where the discharge pipework is shorter than 4mm in total the pump suction pipework must remain at 25mm minimum diameter and be as short as possible and insert the stop valve supplied between the boiler and the check valve It is essential to protect the feed water pump from damage by foreign matter a strainer should therefore be fitted in the pump suction pipework Care should be taken to ensure the pipework is properly aligned and not placing any strain upon the feed water pump 1 The boiler feed water pump may contain an inhibitor and this should be flushed from the pump prior to fitting the pump to the boiler Failure to do so may result in water bounce or foaming due to the inhibitor forming a seal in the boiler 2 If the boiler is to be operated with little or no condensate return consideration should be given to pre heating the feed water If in doubt consult Fulton Boiler Works 3 The Feed water inlet connection on some boilers is located on the left hand side of the boiler below the sight glass assembly Feed Water Check Feed Water Stop Valve Valve Dip Pipe Supply FIG 5 BOILER FEED WATER ARRANGEMENT J OIL E 08 2008 Fulton 2 6 BLOWDOWN VALVE f ra FIG 6 BOILER BLOWDOWN models 20 60 2 6 1 BLOWDOWN VALVE
57. intain Maintain Pressure Water Ignition Electrodes Main Air Adjustment Oil Valves Photoelectric Cell Low Water Probes Low Water Control Pressure Controller Burner Programmer Transformer Sec Air Adjustment Loss of Priming Oil Steam Overload Feed water Pump Bad Traps Dirty Flues FIG 16 FAULT FINDING CHECK LIST J OIL E 08 2008 30 3 3 This log should be completed regularly as a record of boiler maintenance MAINTENANCE LOG 31 J OIL E 08 2008 4 4 1 MAINTENANCE SECTION 4 GENERAL To ensure the efficiency of the boiler carry out the regular maintenance instructions detailed below If any fault is found during these operations contact your Fulton representative CAUTION It is essential that regular checks are made to ensure that scale buildup is not taking place within the boiler Such checks will ensure that water treatment being applied to the boiler feed water is effective 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 handhole door is removed Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions
58. le sealant on all joints The gauge should be facing front towards the electrical control box and or the operator of the boiler Screw the assembly into the top of the boiler and connect the copper tube from the pressure controller located on the side of the control box to the nipple provided on the assembly 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 is not only correct but is operating safely and at optimum efficiency FLUE COMMISSIONING Prior to initial firing of the boiler the flue must be checked for leaks This is done by BOTH of the following methods Visual Inspection Check joints between all flue sections for quality of seals Where the flue passes through the structure of the building use your judgement as to the integrity of this section of the flue Smoke Test With the flue capped the drain stabilizer pipe if fitted blanked and a smoke generator inserted into the flue there should be no smoke visible from the flue If 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 Boiler Works Immediately 11 J OIL E 08 2008 2 Fulton 2 2 16 COMMISSIONING THE BOILER continued INSPECTION a Ensure the boiler has been washed o
59. ler house should be sufficiently large to allow easy and safe access to all parts of the boiler for installation operation and maintenance purposes Reference should be made to Section 5 General Data to ascertain the relevant dimensions and special note taken of the vertical clearance required for the removal of the burner The flooring must be level laid in a non combustible material and be of sufficient strength to support the boiler VENTILATION Adequate fresh clean air is necessary for safe and efficient combustion and should be provided at high and low level in accordance with IGE UP 10 Edition 2 It is essential that only fresh air is allowed to enter the combustion air system Foreign substances such as combustible and volatile materials in the combustion system can create hazardous conditions Note a Ensure there is adequate ventilation in the boiler room Lack of ventilation will create a high temperature and cause control lockout b Do not keep exhaust fans running with windows doors and vents closed this will interfere with the necessary boiler draught c Do not store chemicals such as perclorethylene in the boiler house the fumes may damage the boiler and flue and cause the burner to lock out on flame failure Ventilation requirements Boiler Model 6J 8J 107 15 203 303 40K 50 60J High Level cm 305 360 420 560 700 980 1260 1540 1820 Low Level 614 720 835 1115 1395 1960 2520 3085 3645
60. mp interrupt pump run switch b Open the water column blowdown valve for 5 seconds c Close the water column blowdown valve Wait for 10 seconds for the water in the boiler to stabilise after blowdown d Switch the pump on at the pump interrupt pump run switch Australian Boilers only Water Column Blowdown 1 Place the sequence valve lever into the blowdown column position A 2 Open the Column blowdown valve B for 5 seconds then CLOSE 3 Place the sequence valve lever into the blowdown leg position C 4 Open the Column blowdown valve B for 5 seconds then CLOSE 5 Return the sequene lever to the working m B DOWN LEG WORKING POSITION Operating handle FG00140 shown in the blowdown position Fig 14 SEQUENCING BLOWDOWN VALVE J OIL E 08 2008 22 3 Fulton 3 3 7 BLOWDOWN PROCEDURES Daily tests continued Water Gauge Blowdown a Blowdown the water gauge set 1 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 WORKING STEAM WATER POSITION BLOWDOWN BLOWDOWN Open the gauge glass blowdown valve A Close for approx 3 seconds the top gauge valve B Open valve B Close for approx 3 seconds the bottom gauge valve C Open Close valve A
61. ng Tighten or replace Check for seized pump shaft Replace Burner back fires 1 Refractory Bricks Check the bricks are not plugged with soot or broken into pieces Clean and replace as required 2 Ignition Electrodes Check electrodes for carbon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace 3 UV Detector Check for dirt on scanner clean as required Check for proper location of detector 4 Draft Problem Check draft is neutral Consider installing a barometric damper if the draft is too strong 5 Negative Room Pressure Ensure no exhaust fans are running in the boiler room 6 Primary Air Adjustment Check air adjustment Air may be blowing fire away from flame detector 7 Oil Valve s Check for leaking oil valve s and replace 8 Loss of Oil Prime Check all lines for possible air leak in intake line and tighten Check for possible restricted intke line Replace 9 Loose Oil Fittings Check all fittings and tighten 10 Blocked Oil Filter Check and clean or replace 11 Blocked screen in Oil Pump Check and clean or replace 12 Blocked Flue Check flue is not blocked clean as required Check draft at flue 13 Vacuum on Pump Check for too high a vacuum on the pump Check oil lines and distance from tank to boiler Repaire or replace as necessary 14 Hole in suction line Check and replace as necessary 27 J OIL E 08 2008 Fulton Wi 3 11 TROUBLESHOOTING
62. nspection FIG 1 OIL FIRED STEAM BOILER 1 J OIL E 08 2008 1 1 1 2 INTRODUCTION SECTION 1 General The Fulton Series J Oil Fired Steam Boiler is a vertical two pass boiler of simple and efficient design and construction Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained Satisfactory performance can only be ensured if the installation recommendations operating routines and maintenance schedules laid out in this manual are adhered to Particular attention should be paid to electrical installation and water treatment Technical Data for a full specification refer to Section 5 BOILER MODEL 15J 20J 30J 40J 50J 60J Performance Output kg h 100 C J OIL E 08 2008 2 Flame Main Detector Steam Valve Feed Water and Check Valves Pressure Gauge Ignition Oil Feed Electrodes Steam Pressure Steam Valve Gauge to Feed Water Pressure Valves Controllers Ignition Water Level Transformer Probes TDS System Feed Water Supply FIG 2 BOILER TOP VIEWS 3 J OIL E 08 2008 2 1 2 2 2 3 INSTALLATION SECTION 2 GENERAL The installation of a Series J Oil 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 SITING The boi
63. rogrammer Flame Failure Alarm reset This switch will illuminate if the burner goes to a lockout condition due to flame failure Pressing the switch will reset the burner controller WARNING No more than two attempts should be made to start the boiler by resetting the flame failure alarm reset Further attempts could cause the boiler and flue system to fill with vaporized oil which could cause an explosion Oil Valve The two lamps provide a visual indication that the magnetic oil valves have been energised Low Flame Start and Main Flame Models 40J and 60 are fitted with the following indicator lamps in place of the two oil valve indicator lamps The burners on models 40J and 60J are fitted with a two stage combustion system The low flame start lamp indicates that the first stage of combustion is in progress and that the burner should be firing Once the second stage of combustion is reached full firing position the low flame start lamp extinguishes and the main flame lamp illuminates This lamp will remain illuminated until the burner is shut down J OIL E 08 2008 18 34 FILLING THE BOILER ALL MODELS Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down a Ensure that the main steam stop valve is OPEN b Ensure that the steam pressure gauge isolating valve is OPEN c Ensure that the oil flow and return
64. rst low water alarm sounds Switch the pump interrupt switch to the pump interrupt position and the low water indicator lamp illuminates and the burner shuts down 4 Switch the pump interrupt switch to the pump on position 5 6 After approximately 17 seconds from restoring the first low water level the low water alarm will The pump will start and restore the water level to the normal position and switch off cancel the low water lamp will extinguish and the burner will restart Low Water With the burner firing Switch the pump interrupt switch to the pump interrupt position 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 Switch the pump interrupt switch to the pump on position The pump will start and restore the water level to the normal position and switch off After approximately 17 seconds from restoring the second low water level the second low water relay can be reset To cancel the second low water level alarm and light depress the second low water reset switch The burner will restart Note These tests can be carried out consecutively however it is possible that if the boiler is under load conditions the second low water alarm will occur immediately after the burner has shut down on first low water without the apparent loss of any more water The reason is the collapse of the steam bubbles at the wat
65. s 3 7 Evaporation Checks 3 8 Draining the Boiler 3 9 Long Term Shut Down 3 10 Troubleshooting 3 11 Maintenance Log MAINTENANCE 4 General 4 1 Daily 4 2 Weekly 4 3 Monthly 44 Three Monthly 4 5 Six Monthly 4 6 GENERAL DATA 5 SPARE PARTS 6 J OIL E 08 2008 Wi Fulton SAFETY The 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 WARNING It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a correct and safe manner Z WARNING Do 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 WARNING Understand the electrical circuit before connecting or disconnecting an electrical component A wrong con nection can cause injury and or damage N WARNING Adefective boilercan injure you or others Do not operate a boiler which is defective or has missing parts Make sure that all maintenance procedures are completed before using the boiler WARNING HYDRAULIC TEST RISK OF BRITTLE FRACTURE Hydraulic testing requires specialist equipment and is normally only required by engineering surveyors in spectors The materialthe boileris manufactured from has not been impact tested as it is not a requirement of BS2790 boiler construction standard In order
66. sher spring 300 amp 350 6 60 9 10842 10 Washer 300 amp 350 6 60 10 12227 3 Plug 300 amp 350 6 60 J OIL E 08 2008 December 2004 Fulton G2 1 1 CONTROL BOX ASSEMBLY OIL 6 15 su m E ip aAa December 2004 J OIL E 08 2008 Fulton G2 1 1 CONTROL BOX ASSEMBLY OIL 6 15 Item Part Number Qty Description Remarks Size 1 004EO322UK 1 Control Box assy 240V 1 50 6 15 004EO324UK 1 Control Box assy 400V 3 50 6 15 2 10448 1 Switch isolator 25Amp 6 15 3 10496 2 Contactor 220 240V 6 15 4 10507 2 Contactor n open 3ph only 6 15 5 11327 1 Switch single pole 6 15 6 11526 1 Switch rocker Amber 6 15 7 11587 1 Switch rocker Black 6 15 8 11596 3 Relay miniture 4 pole 6 15 9 11597 3 Base miniture relay 4 pole 6 15 10 11667 1 Lamp indicator red 6 15 11 11737 2 Contact aux CBA 10 3ph only 6 15 12 11793 1 Facia 6 15 13 11829 1 Base burner control 6 15 14 11831 1 Control burner BH064 240 6 15 15 11869 3 Relay LC3 6 15 16 11904 3 Base LC relay 11 pin DIN 6 15 17 11941 1 Breaker circuit 3ph only 1 0 1 6 6 15 12019 1 Breaker circuit 1ph only
67. ton D2 3 1 BURNER SCROLL ASSEMBLY OIL 40 60 Item Part Number Qty Description Remarks Size 1 050E0340 1 Scroll assembly 40 50 060 0340 1 Scroll assembly 60 2 SA0010 1 Mesh air gate 40 60 3 10239 1 Transformer 2P 240V 40 60 4 10268 1 Pump oil AJ6CE 40 60 5 10277 1 Fan 10in x 2 1 2in 50 10279 1 Fan 10in x 3in 60 6 10281 1 Coupling pump 4in 40 60 7 10282 1 Coupling pump rubber DX 40 60 8 10286 3 Valve solenoid 1 8in BSP 40 60 9 10350 1 Nipple pressure test 40 60 10 10368 1 Casting scroll 40 60 11 10375 1 Casting damper 40 60 12 10577 3 Nipple barrel 1 8in 40 60 13 10578 1 Nipple pipe 1 8in x 3in 40 60 14 10655 2 Plug 1 4in 40 60 15 10692 1 Tee 1 8in 40 60 16 10720 3 Elbow 40 60 17 10755 1 Box conduit 75x 75 x 37 40 60 18 10786 2 Bolt set 6 x 16mm plated 40 60 19 10800 4 Nut M10 plated 40 60 20 10807 4 Screw allen 8 x 20mm 40 60 21 10786 2 Bolt M6 x 16mm plated 40 60 22 10841 2 Washer M6 plated 40 60 23 10844 4 Washer M10 plated 40 60 24 10849 3 Washer spring M6 plated 40 60 25 10851 4 Washer spring M10 plated 40 60 26 11033 4 Washer 1 4in plated 40 60 27 11147 1 Nut wing M6 plated 40 60 28 11418 4 Washer shake proof 10mm 40 60 29 11419 4 Screw csk M10 x 40 40 60 30 11975 1 Motor 1 5kW 3ph 40 60 11024 1 Motor 1 5kW 1ph 40 60 31 0202046005 1 Gate assembly air 40 60 32 10146 A R Insulation 6mm glass yarn 40 60 33 A R Grubscrew M6 x 1
68. ut after installation Conduct a water analysis before operating the boiler Examine the probes in the water column and the boiler shell Replace any damaged probes b Remove the burner and check the electrodes have not been damaged that their settings are correct If the burner is fitted with a photocell remove it and check for damage c Replace the burner and reconnect the cooper oil line s to the oil nozzle assembly ensuring these connections are tight Reconnect the ignition leads and replace the sensor d X Ensure all wiring connections are correct and all terminal screws are tight Fire Oil Supply Low Fire Start Burner Plate cg Supply B Electrodes Electrodes View on arrow A omm do 12m om rO Electrode settings 22 EJ relative to nozzles 130mm 5mm Fuel Nozzle Electrode Tips Bent to align with 300mm 212 Low Flame Start 2 5mm 80 Spray oil supply nozzle Arrow B Nozzle Manifold 5mm Y 15 12mm 300mm 7 80 Spray View on arrow 12mm High Fire Oil Supply era Low Fire Oil Supply F00870 SINGLE NOZZLE RO SINGLE STAGE LIGHT 40E 60E Tenue Note Always place the highest value nozzle engraved on the side of the nozzle into the low fire oil supply port in
69. valves are OPEN that there is an adequate oil supply in the oil tank and that the burner oil pump has been vented d X Ensure that all the valves in the water feed line are OPEN e Ensure that the main blowdown valve is CLOSED f Ensure that the water level gauge isolating valve s is OPEN g Ensure that the water level gauge blowdown valve s is CLOSED h Ensure that the column blowdown valve is CLOSED i Ensure that the boiler and pump switch is in the OFF position j Ensure that all appropriate electrical isolators are switched ON k Ensure the pump interrupt switch is in the PUMP RUN position 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 fully primed before energising the motor 1 Press the boiler pump switch to the PUMP ONLY position Note f the boiler water level is below its correct level the water pump will operate When the water reaches the correct level two thirds up the water level gauge sight glass the pump will stop If the water level is above the top of the water level gauge sight glass drain off until the level is in the middle of the water level gauge sight glass 3 5 STARTING THE BURNER a CLOSE the main steam stop valve b Press the control switch to the PUMP AND BOILER position The low water audible alarm will sound and the low water reset switch and low water alarm lamp will illuminate c Press th
70. week to allow all impurities to flush through d Drain the boiler completely each day e X After the week is completed drain and flush the condensate return tank removing all installation sediment Reconnect the condensate return pipe to the condensate return tank 15 J OIL E 08 2008 3 3 1 3 2 OPERATION SECTION 3 GENERAL The following instructions are given for the guidance of the operator in the use of the J Series gas fired 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 this water is driven off by chemical reaction and the initial test firing the refractory is still wet when the boiler is delivered For the first few days after the boiler is commissioned and in service water will be seen running from the bottom of the casing and from around some branch pipes This is perfectly normal and part of the final drying process BOILER CONTROLS The following brief description of the controls used on the Series J Oil Fired Boiler is intended to provide the operator with a basic understanding of the oper
71. y by a qualified boiler at 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 Daily Test 1st Low Water 1 2 3 4 2nd With the burner firing Press and hold the 1st Low Water test button until minimum 15 seconds the low water alarm sounds and the low water indicator lamp illuminates and the burner shuts down Release the test button After approximately 17 seconds the low water alarm will cancel the low water lamp will extinguish and the burner will restart Low Water 1 With the burner firing Press and hold the 2nd Low Water test button until minimum 15 seconds the low water alarm sounds and the second low water reset switch illuminates and the burner shuts down Release the test button After approximately 17 seconds the second low water relay will reset To cancel the second low water level alarm and light depress the second low water reset switch The burner will restart J OIL E 08 2008 38 Fulton Spirax High Integrity Level Controls continued Weekly Test Daily test plus 1st Low Water 2nd ous G 8 1 With the burner firing 2 3 By evaporation lower the water level in the boiler until the fi
72. zzle 8 Transformer 9 Burner Control 10 Pressure Control Remedy Check fuse or circuit breaker Reset or replace as necessary Disconnect all power to the controller Disconnect the wires from the controller connect an ohmmeter between the switch terminals Lower the set point of the controller the switch should make raise the set point and re check switch should break if the controller operates improperly replace it Refill the oil tank A slight delay in the re priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily Check fuse or Circuit breaker Reset or replace as required Check electrodes for carbvon build up clean if required Check settings adjust if required Check for cracks in porcelain if found replace Check for dirt on detector clean as required Check for proper location of detector Check for faulty air switch by jumpering the two air switch leads at the terminal block If the boiler starts and runs with the jumper in place the air switch should be replaced Check the level control relays are securly mounted on their bases Check the power supply to each The relays may be checked by swopping positions and checking they are both functioning Check for clogged nozzle clean or replace Check voltage between transformer neutral at terminal block to be sure transformer is being powered Check voltage between pilot terminal and neutral

`J` SERIES - OIL FIRED STEAM BOILERS (6J - 60J)

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