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Water Level Probe Info INSTALLATION, OPERATION AND MAINTENANCE MANUAL J Series (UK) Gas Fired Steam Boiler (including optional fully modulating burner) This manual must be available to the boiler operator at all times. JGASUK-IOMM-2015-2 Fulton Ltd Page II JGASUK-IOMM-2015-2 Fulton Ltd TABLE OF CONTENTS SECTION 1 - INTRODUCTION 4.10 Internal Inspection 32 1.1 General 1 4.11 Schedule of Operator Tests and Checks 33 1.2 Technical Data 1 4.11.1 Daily 34 4.11.2 Weekly-in addition 34 SECTION 2 - INSTALLATION 4.11.3 Monthly-in addition 34 2.1 General 3 4.11.4 Three Monthly-in addition 35 2.2 Siting 3 4.11.5 Six Monthly-in addition 35 2.3 Ventilation 4 4.11.6 Annually-in addition 37 2.4 Flue Outlet 4 4.12.1 Troubleshooting-boiler 38 2.5 Water Supply 6 4.12.2 Troubleshooting-feedwater pump 41 2.6 Blowdown Valve 7 4.12.3 Troubleshooting-burner control unit-LFL1 43 2.7 Main Steam Valve 8 4.13 Maintenance Log 45 2.8 Steam Safety Valves 8 2.9 Water Level Gauge Set (sight glass) 8 APPENDIX A - TI SHEETS 2.10 Gas Supply 8 APPENDIX B - WATER LEVEL PROBE INFO 2.10.1 Gas Valve with Pilot Gas Line 9 2.11 Electrical Requirements 9 APPENDIX C - MOTORISED HIGH/LOW CONTROL 2.12 Steam Pressure Gauge 9 1.1 General 57 2.13 Commissioning the Boiler 11 1.2 Operation 57 2.13.1 Boiler Inspection and Initial Firing 11 1.3 Additional Controls 58 2.13.2 Setting Burner Controls-low/high fire (40J-60J) 14 1.4 Commissioning 58 2.13.3 Setting Burner Controls-fully modulating (30J-60J) 14 1.4.1 Fuel Input Rates 58 2.14 Multi Bloc Gas Valves 15 1.4.2 Air Damper Motor - Factory Cam Settings 58 2.15 Cleaning Steam Lines and Pressure Vessels 18 1.4.3 Setup Procedure 59 1.5 Spare Parts 59 SECTION 3 - OPERATION 3.1 General 19 APPENDIX D - SPIRAX HIGH INTEGRITY LEVEL 3.2 Boiler Controls 19 3.3 Indicator Lights 21 CONTROLS 3.4 Filling the Boiler-all models 22 1.1 Daily Tests 61 3.5 Starting the Burner-all models 23 1.1.1 1st Low Water-daily 61 1.1.2 2nd Low Water-daily 61 SECTION 4 - MAINTENANCE 1.2 Weekly Test-in addition 62 4.1 Visual Checks 25 1.2.1 1st Low Water-weekly in addition 62 4.2 Water Level and Low Water Safety Controls 25 1.2.2 2nd Low Water-weekly in addition 62 4.2.1 Pump Test 25 4.2.2 1st Low Water Level Check 26 APPENDIX E - AUTOMATIC TDS BLOWDOWN 4.2.3 2nd Low Water Level Check 27 4.3 Main Blowdown 28 SYSTEM 4.4 Water Column Blowdown 28 1.1 General 63 4.5 Water Level Gauge Blowdown 29 4.6 Evaporation Checks 30 4.7 Flame Sensor Test 30 4.8 Draining the Boiler 31 4.9 Long Term Shut Down 32 Electrical diagrams supplied separately JGASUK-IOMM-2015-2 Page III WARNINGS Fulton Ltd ! CAUTION 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, whatever the cause, then the fuel supply to the boiler should be isolated immediately, until the fault has been investigated by a competent person and rectified. For your safety! The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual. • WARNINGS must be observed to prevent serious It is the responsibility and duty of all personnel involved injury or death to personnel. in the operation and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and • CAUTIONS must be observed to prevent damage NOTES by which hazards are to be eliminated or or destruction of equipment or loss of operating reduced. effectiveness. Personnel must become familiar with all aspects of • Notes: must be observed for essential and safety and equipment prior to operation or effective operating procedures, conditions and as maintenance of the equipment. a statement to be highlighted. ! WARNING Steam boilers are a potential hazard, possibly fatal if not properly maintained. ! CAUTION 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 system and increase the possibility of fire, explosion, property damage, personal injury or loss of life. The Pressure System Safety Regulations 2000 Fulton boilers fall within the scope of the Pressure Systems Examination Scheme. Regular inspections are therefore required by a competent person. The scope of the examination and the actual intervals between examinations is at the discretion of the competent person. It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which a defect may give rise to danger. Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover periodic statutory inspections. For further information contact: (a) SAFed SAFETY ASSESSMENT FEDERATION Limited. Nutmeg House, 60 Gainsford Street, Butlers Wharf, London, SE1 2NY. (b) Health and Safety Executive local office. (c) Your Competent Person. Page IV JGASUK-IOMM-2015-2 Fulton Ltd WARNINGS 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 heater and serious personal injury. ! WARNING !! WARNING Do not try to do repairs or any other maintenance work DANGER FROM INCOMPLETE COMBUSTION you do not understand. Obtain a service manual from The importance of correct burner adjustment to achieve Fulton Ltd or call a Fulton service engineer. low emissions, safe, clean and efficient combustion is paramount. Poor combustion, where unburnt gas It is the responsibility of the installer to ensure all parts forms carbon monoxide is both a health hazard, and supplied with the boiler are fitted in a correct and safe the potential risk to the boiler from overheating, caused manner. by re-burning of the unburnt gas in the secondary flue passes. Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong Prior to the commencement of any work requiring the connection can cause injury and or damage. removal of cover plates and the opening of control panel box, the electrical supply to the boiler must be isolated. A defective boiler can injure you or others. Do not operate a boiler which is defective or has missing parts. Make sure that all maintenance procedures are ! CAUTION completed before using the boiler. Obey all laws and local regulations which affect you and Do not change the boiler fuel without consulting the your boiler. boiler manufacturer. LOW FEEDWATER TEMPERATURE LIFTING EQUIPMENT Low feedwater temperature can result in thermal shock Make sure that lifting equipment complies with all local to the boiler pressure vessel. Return the maximum regulations and is suitable for the job. You can be injured amount of condensate and if necessary preheat the if you use faulty lifting equipment. Make sure the lifting feedwater. If in doubt consult Fulton Ltd. equipment is in good condition. WATER SOFTENER and CHEMICAL TREATMENT Operating the boiler beyond its design limits can damage The chemicals required to operate the water softeners the boiler, it can also be dangerous. Do not operate the and chemical treatment plants CAN BE SUPPLIED by boiler outside its limits. Do not try to upgrade the boiler Fulton Ltd. performance by unapproved modifications. It is the responsibility of the operator to ensure adequate supplies of chemical are available at all times Non-approved modifications can cause injury and (including commissioning). Costly repairs could be damage. Contact your Fulton dealer before modifying required should the plant operate without chemicals or the boiler. the wrong dosage of chemicals. Only qualified persons should be allowed to HYDRAULIC TEST - RISK OF BRITTLE FRACTURE operate and maintain the boiler and its equipment. Hydraulic testing requires specialist equipment and Boilers should always be drained through an approved is normally only required by engineering surveyors / blowdown vessel. inspectors. In order to ensure the material/ pressure vessel does not suffer from brittle fracture, hydraulic The installation of gas appliances including the testing should not be carried out below 7 °C. flue system should only be carried out by Gas Safe registered engineers. Steam boilers have high temperature surfaces, that if touched may cause serious burns. Only competent and qualified personnel should work on or in the locality of a steam boiler and ancillary equipment. Always ensure the working area and floor are clear of potential hazards, work slowly and methodically. Do NOT store inflammable materials near the boiler. The importance of correct boiler water and feedwater cannot be over emphasised, see the relevant section in this manual. JGASUK-IOMM-2015-2 Page V Fulton Ltd Pressure gauge Monobloc gas valve Air pressure switch Low water level probes Water column containing water level probes Air intake Water level gauge (sight glass) Boiler control panel Water level gauge blowdown valves Control box Water column door lock blowdown valve Steam pressure control Control box isolator switch Steam pressure limiter Clean out handhole (water jacket) Clean out door (furnace) Figure. 1 - Non-Modulating Gas Fired Steam Boiler Page VI JGASUK-IOMM-2015-2 Fulton Ltd INTRODUCTION - 1 SECTION 1 - INTRODUCTION 1.1 GENERAL The Fulton J Series gas fired steam boiler service manual is a generic publication, providing information on standard boiler operation and maintenance.
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