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. The J Series gas fired steam boiler is a vertical two-pass boiler of simple, 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.

1.2 TECHNICAL DATA

For a full specification refer to Appendix A - TI-117-J Series Dimensions & Specification.

! CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants CAN BE 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.

JGASUK-IOMM-2015-2 Page 1 Fulton Ltd

Pressure gauge

Air pressure switch

Low water level probes

Water column Air intake containing water containing main air level probes control

Water level gauge (sight glass) Boiler control panel

Water level gauge blowdown valves AZL burner control Water column blowdown valve

Pressure transducer Control box door lock

RWF40 PID Controller Control box isolator switch BT1050 Steam pressure Boiler blowdown limiter timer (if fitted)

BC3150 Blowdown controller (if fitted) Clean out handhole (water jacket) LC3050 Level limiters (if fitted)

Clean out door (furnace)

Figure. 2 - Fully Modulating Gas Fired Steam Boiler

Page 2 JGASUK-IOMM-2015-2 Fulton Ltd INSTALLATION - 2

SECTION 2 - INSTALLATION

2.1 GENERAL

The installation of a J Series gas fired steam boiler should be carried out by competent personnel in accordance with all relevant safety regulations. It is the responsibility of the installer to ensure that these regulations are complied with.

The requirements and instructions contained in this section generally relate to the boilers being installed to operate on natural or manufactured gas. Where the boiler is to operate on L.P. Gas, special reference should be made to Section 2.10 - Gas Supply, and Section 2.16 L.P. Gas Supply.

2.2 SITING

(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1 Communication 1676, and in particular to Section 5, Location of Appliances).

The boiler house should be sufficiently sized to allow easy and safe access to all parts of the boiler for operational and maintenance purposes.

Reference should be made to Appendix A - TI-117-J Series Dimensions & Specification to ascertain the relevant dimensions and weights, special note should be taken of the required vertical clearance required for maintenance.

! WARNING Maintenance on the burner assembly requires the area directly above and to one side of the boiler must not be obstructed with pipework or equipment which would interfere with the removal of the complete burner unit. Care should be taken on installation of the boiler to ensure this area remains clear of obstructions.

The flooring must be level, laid in a non-combustible material and be of sufficient strength to support the boiler.

JGASUK-IOMM-2015-2 Page 3 INSTALLATION - 2 Fulton Ltd

2.3 VENTILATION

Adequate fresh, clean air is necessary for safe and efficient combustion, and should be provided at high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part 1 Communication 1676.

Note: Ensure that there is adequate ventilation in the boiler room. Lack of ventilation will create a high temperature and cause control lockout. There is a minimum ventilation requirement to supply the air for combustion.

Note: Do not keep exhaust fans running with windows, doors and vents closed, this will interfere with the necessary boiler draught.

Note: 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.

Note: see Appendix A - TI-117-J Series Dimensions & Specification for low and high level values.

2.4 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 be subject to local planning regulations and approvals.

The following information is only intended to provide assistance for the installation of a simple flue. Where multi-boiler flues or difficulties are experienced, specialist advice 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 metre 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.

Note: If the flue layout is such that it may produce an excessive up-draught, a draught stabiliser may be required.

Note: Avoid fitting 90° elbows whenever possible, if unavoidable compensate by increasing the flue diameter.

Note: Ensure all flue pipes from the boiler to the main flue have a rising pitch.

Figure. 3 - Boiler Flue Connection

Page 4 JGASUK-IOMM-2015-2 Fulton Ltd

Cowl

Pipe safety valve to a safe area, H using unions and drain as required. Standard boiler trim D D = Diameter of flue Steam supply Feedwater isolation ball valve supplied with boiler H = 1.5 X D

Flue

Vent to Draught stabiliser Atmosphere (when fitted) Note: A break tank may be required depending Flue spigot upon Local Water Authority bylaws Clean-out door

Boiler Water Level Overflow Make-up feedwater supply Feedwater non-return Stainless steel Flexible valve feedwater and (to be installed below connector condensate boiler water level) Vent return tank Water column Flanged connection blowdown line 20J - 60J only Condensate return Blowdown Separator Feedwater pump Overflow to drain

Boiler blowdown valve Drain

F03164 Strainer Plugged drains Isolating gate/ball valve

Figure. 4 - Typical Installation

JGASUK-IOMM-2015-2 Page 5 INSTALLATION - 2 Fulton Ltd

2.5 WATER SUPPLY

The quality of the water used in the boiler will affect the life and performance of the boiler. Feedwater contains solids and dissolved gases, these may promote encrustations of scale; foaming, priming, surging; corrosion and pitting; or caustic embrittlement. To prevent this happening it is strongly recommended that a reputable water treatment concern is consulted prior to commissioning the boiler.

Note: See Appendix A - TI-139-Recommended Water Conditions.

Connect the feedwater pump discharge to the check valve inlet with 25 mm bore pipe (this may be reduced to 15 mm, where the discharge pipework is shorter than 4 m in total. The pump suction pipework must remain at 25 mm minimum diameter and be as short as possible). Install the stop valve supplied between the boiler and the check valve. The check valve must be positioned so that it is below the internal water level of the boiler, and should be installed at least 1 m after the feedwater pump. The reason for this placement position is that the check valve is designed to have water on both sides to enable it to function correctly.

It is essential to protect the feedwater pump from damage by foreign matter, a strainer should therefore be fitted in the pump suction pipework.

Care should be taken to ensure the pipework is properly aligned and not placing any strain upon the feedwater pump.

Note: The boiler feedwater 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.

Note: If the boiler is to be operated with little or no condensate return, consideration should be given to pre-heating the feedwater. If in doubt consult Fulton Ltd.

Note: The feedwater inlet connection on some boilers is located on the left hand side of the boiler below the sight glass assembly.

Feedwater stop valve Feedwater dip pipe

Feedwater line

Check valve

Figure. 5 - Boiler Feedwater Arrangement

Page 6 JGASUK-IOMM-2015-2 Fulton Ltd INSTALLATION - 2

2.6 BLOWDOWN VALVE

There are four blowdown valves on the boiler, the boiler blowdown valve at the rear of the boiler, the water column blowdown valve and two water level gauge (sight glass) blowdown valves.

All of these valves must be connected to a blowdown receptacle of approved design. Regulations exist covering such items and care must be taken to ensure compliance with these regulations.

If in doubt regarding blowdown arrangements, consult Fulton Ltd.

Note: 8J - 15J main blowdown connection is via a branch pipe.

Note: 20J - 60J main blowdown connection is integral, via a boiler mounted flange. Where possible the main blowdown pipework on 20J - 60J boilers should drop down to a union connection to allow removal of the inspection flange without the necessity to remove the blowdown pipework.

Figure. 6 - Boiler Blowdown- models 8J - 15J (skid Figure. 7 - Boiler Blowdown- models 20J - 60J mounted boiler shown) (skid mounted boiler shown)

JGASUK-IOMM-2015-2 Page 7 INSTALLATION - 2 Fulton Ltd

2.7 MAIN STEAM VALVE

The main steam stop valve should be inserted in the steam line approximately 305 mm from the top of the boiler.

2.8 STEAM SAFETY VALVES

Safety valves are factory fitted and pre-set, 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.

Note: It is recommended that the safety valve discharge pipework is installed to the requirements of BS806 clause 4.9.7. / BSEN 134801-1:2002

a) The lift pressure is indicated on the safety valve (do not adjust). b) The safety valve fitted to the boiler is designed to prevent the boiler exceeding its design pressure. c) Any system connected to the boiler not capable of accepting boiler pressure must be protected by a separate safety valve set to the required pressure.

! WARNING Factory fitted safety valves are pre-set to protect the boiler only and must not be used to protect any other items not capable of accepting boiler pressure.

2.9 WATER LEVEL GAUGE SET (SIGHT GLASS)

Boilers are normally supplied with two complete water level gauge sets (sight glasses). The water level gauge blowdown cock should be connected to the auxiliary blowdown line from the water column blowdown valve by 3/8 in. soft copper tubing.

2.10 GAS SUPPLY

Verify that the burner is suitable for the type of gas being supplied. Ensure that the piping from the meter is the correct size, and that a gas cock is inserted in the line between the boiler and the meter. To avoid pressure drops, eliminate all unnecessary bends and elbows in the pipework between the gas meter and the boiler. A scale trap is provided on the gas train and should be used. Burners suitable for operation on natural and manufactured gas are supplied with gas trains or a modular gas head. A minimum pressure of 18 mbar at the specified flow rate, is required at the gas train for natural gas installations and a minimum pressure of 50 mbar is required at the gas train for manufactured/L.P gas installations. If the gas supply is in excess of 100 mbar for Natural gas a suitable regulator is required before the main gas valve. Burners arranged for operation on L.P. gas are supplied with gas trains. It is essential that the MAXIMUM pressure of the gas at the gas train does not exceed 80 mbar and does not fall below 50 mbar. A suitable regulator is required before the main gas valve. To obtain these pressures, a pressure regulating device or service governor must be fitted to the supply line from the storage tank to the boiler gas train. Careful consideration must be given to the siting of LPG storage tanks to prevent over pressure conditions arising, due to temperature rises caused by solar gain.

Page 8 JGASUK-IOMM-2015-2 Fulton Ltd INSTALLATION - 2

2.10.1 GAS VALVE WITH PILOT GAS LINE

Models 40J - 60J

The main gas valve is fitted with a bypass system (internal or external depending on the model) the bypass allows pilot pressure to be maintained whilst the flame is verified.

2.11 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 feedwater pump motors arranged for operation on a three phase supply. The power ratings and requirements are given in Appendix A - TI-117-J Series Dimensions & Specification.

2.12 STEAM PRESSURE GAUGE

The steam pressure gauge assembly should be assembled in accordance with Figure. 8 using a suitable 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.

Steam Pressure Gauge

Plugged

Steam Cock

Test Point

Syphon

Figure. 8 - Steam Pressure Gauge

JGASUK-IOMM-2015-2 Page 9 INSTALLATION - 2 Fulton Ltd

Pressure gauge

Air proving Gas train with switch 360° rotation Burner scroll

Feedwater stop valve Low level water Secondary air probes control TDS system Steam safety valve Feedwater line

Feedwater check valve

Note: Boiler illustrated is fitted with optional Self Monitoring Controls.

Figure. 9 - Boiler Top Components (non modulating burner)

Gas train with 360° rotation Steam pressure gauge Steam out

Air pressure Feedwater line switch Air actuator TDS system

Burner scroll

Figure. 10 - Boiler Top Components (fully modulating burner)

Page 10 JGASUK-IOMM-2015-2 Fulton Ltd INSTALLATION - 2

2.13 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:

a) 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.

b) Smoke Test With the flue capped, the drain stabiliser 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 Ltd immediately.

Note: Flues that are designed to operate with positive pressure should be tested to the latest regulations.

2.13.1 BOILER INSPECTION AND INITIAL FIRING

1. Ensure that the boiler has been washed out after installation. It is advisable to conduct a water analysis before operating the boiler. Examine the probes in the water column and the boiler shell and record their lengths. Replace any damaged probes.

2. If the burner is fitted with an ultraviolet or solid state detector, remove the detector and check for damage. Remove the burner and check that the electrodes have not been damaged and that their setting corresponds to the appropriate drawing.

3. Check that the burner is the correct type for use with the gas being supplied.

Main Gas Supply

Ultraviolet Detector Ignition Electrode 297.4 mm

Primary Air Blast Tube 12.7 mm

3 mm min. 5 mm max

50.8 mm

Figure. 11 - Burner Electrode Settings CONTINUED ON NEXT PAGE JGASUK-IOMM-2015-2 Page 11 INSTALLATION - 2 Fulton Ltd

4. Ensure that all wiring connections are correct and that all terminal screws are tight.

5. A barometric type draught stabiliser, if fitted in the flue, should be set for a draught of - 0.025 mbar to - 0.05 mbar of water column pressure with the burner off.

6. Open all the valves in the feedwater line. Close the isolating valve on the discharge side of the feedwater pump. Remove the priming plug from the pump head and slowly fill the pump with water. Replace the priming plug and tighten securely.

7. Check the correct rotation of the pump on the motor fan cover. Start the pump and check the direction of rotation. Vent the pump by means of the vent valve in the pump head. At the same time, open the discharge isolating valve a little. Continue to vent the pump. At the same time, open the discharge isolating valve a little more. Close the vent valve when a steady stream of water runs out of it. 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.

8. Open all the valves in the water feed line. Switch on the feedwater 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 level gauge (sight glass) is reading two thirds full, the pump will stop.

! WARNING Gas purging by qualified persons only.

9. After purging the gas lines of air, start the burner.

For models 40J - 60J with an external pilot gas line, see Section 2.13.2 - Setting the burner controls.

Note: Prove the pilot flame by placing the PILOT HOLD / NORMAL switch into the Pilot Hold position, this will hold the gas valve in the pilot gas position until the pilot flame has been verified.

10. Check the burner control is in the run position.

11. Adjust the gas and main air control gate located on the burner scroll, to obtain a clean

combustion. Measure the levels of CO2 CO and O2 in the exhaust gas and record the results. See typical combustion values given in Appendix A - TI 117.

12. Observe the flame through the eye glass and adjust the secondary air control located on the top of the boiler, so that the flame can be seen passing down the blast tube.

13. Check the operation of the low water safety controls.

14. Adjust the steam pressure control to suit the boiler application. It should be borne in mind that boilers are designed to operate most efficiently at their maximum operating pressure. 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.

Page 12 JGASUK-IOMM-2015-2 Fulton Ltd INSTALLATION - 2

If the pressure control is fitted with a differential scale:

1. Set the main scale pressure to the maximum pressure required (system pressure). Do not exceed the boiler operating pressure.

2. Set the differential scale to it’s minimum pressure. If the pressure control has a fixed differential, i.e. no adjustable differential scale, set the main scale to the maximum pressure required.

When multiple boilers are fitted with a sequence control:

1. Set the main scale and differential scale as above.

2. Set the setback pressure control to the required set back pressure.

Figure. 12 - Pressure Controller

JGASUK-IOMM-2015-2 Page 13 INSTALLATION - 2 Fulton Ltd

2.13.2 SETTING THE BURNER CONTROLS LOW/HIGH FIRE (40J - 60J)

The correct setting for low fire/high fire operation is made by making adjustments to the two stage solenoid valve and the low fire steam pressure switch.

1. Isolate the main gas valve by closing the valve in the gas input line.

2. Screw the pilot gas governor fully down (governor open).

3. Start the burner and where possible meter the pilot gas rate (ideally the pilot gas rate should be 10% of the full gas rate).

4. Check the ignition and pilot stability several times. Record the pilot gas pressure.

5. Open the main gas isolating valve.

6. Set the gas input to the boiler for correct input on high fire. This adjustment should be done where possible by using the gas meter. Adjust the main and secondary air gates to obtain optimum combustion conditions.

7. Adjust the low fire steam pressure switch to cut out at approximately 5 psi below the setting of the main steam pressure control.

8. Adjust the two-stage solenoid valve to obtain a low fire gas input of approximately 80% of high fire.

Leave the air gate adjustments as for high fire.

2.13.3 SETTING THE BURNER CONTROLS FULLY MODULATING (30J - 60J)

The correct setting for fully modulating operation is made by adjusting the parameters via the Siemens LMV burner controller.

All adjustments need to be carried out by a suitably trained service engineer.

All parameter adjustments are password protected.

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2.14 MULTI BLOC GAS VALVES

Main gas line isolating valve

Pilot line Pilot line Pilot line Main gas valve ball valve governor gas valves assembly

Figure. 13 - 40J - 60J Gas Valve (non modulating burner)

Gas Gas actuator governor Gas valve

Figure. 14 - 30J - 60J Gas Valve (fully modulating burner)

JGASUK-IOMM-2015-2 Page 15 INSTALLATION - 2 Fulton Ltd

Note: See attached manufacturers leaflets.

Output pressure controller adjusting screw

Hydraulic Brake Operating indicator

Main gas flow adjustment Adjustable pressure switch

Test point connection Test point connection downstream of Valve 1

Gas output flange Gas input filter cover

Test point connection Test point connection downstream of Valve 2 upstream of Valve 1

Output pressure controller adjusting screw Hydraulic brake

Operating indicator Main gas flow adjustment

Adjustable pressure Test point connection switch downstream of Valve 1

Gas input flange Test point connection downstream of Valve 2

Gas input filter cover Test point connection upstream of Valve 1

Figure. 15 - 6J - 30J Gas Valve (non modulating burner): Major Components

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Hydraulic brake

Main gas flow adjustment

Output pressure controller adjusting screw High fire solenoid

Operating pressure indicators Low fire flow adjustment

Input gas test point

Adjustable pressure switch

Test point 1 downstream (internal leak test) Gas input mounting flange location Test point 2 downstream Test point 1upstream

Figure. 16 - 40J - 60J Gas Valve (non modulating burner): Major Components

GAS ACTUATOR

Servo motor body

Valve coupling

GAS GOVERNOR & VALVE Gas valve

Gas governor Electrical connections

Low gas pressure switch

Gas out flange Gas in flange

Filter & main housing Filter caps

Figure. 17 - 30J - 60J Gas Valve (fully modulating burner): Major Components

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2.15 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.

1. Disconnect the condensate return pipe adjacent to the condensate return tank.

2. Direct the returns to a floor drain or other safe discharge point and make safe.

3. Leave in this position for one week to allow all impurities to flush through.

4. Drain the boiler completely each day.

5. 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.

! WARNING Do not change the boiler fuel without consulting the boiler manufacturer.

2.16 L.P.GAS GAS SUPPLY - PROPANE / BUTANE

Note: LPG Boilers should be installed to the requirements of IGE/UP/10 March 2001. An L.P. gas boiler is similar in design to a natural gas boiler, the main differences are important and must be taken into account when installing the boiler and ordering spare parts. When installing an L.P. gas boiler, the feed from the bulk tank supply must be fitted with a supply governor which is set to reduce the supply feed pressure to the boiler governor to between 50 mbar (min.) and 80 mbar (max.).

For PROPANE: The boiler governor must be adjusted to give a firing pressure of 25 mbar at the test point provided at the elbow on the gas train.

For BUTANE: The boiler governor must be adjusted to give a firing pressure of 20 mbar at the test point provided at the elbow on the gas train.

Gas Pressure Alarm Indicator Light For L.P.G. applications the inlet pressure switch is used to protect the system from over pressure and should be set at 100 mbar.

Page 18 JGASUK-IOMM-2015-2 Fulton Ltd OPERATION - 3

SECTION 3 - OPERATION

! CAUTION The following instructions are given for the guidance of the operator in the use of the Fulton steam boiler. No responsibility can be accepted by Fulton Ltd if these instructions are ignored.

3.1 GENERAL

The following instructions are given for the guidance of the operator in the use of the J Series gas fired steam boiler and to provide adequate information to ensure that when the boiler is put into use it will be done safely and without risk to health. Where original equipment service manuals are supplied, they must be read and understood in conjunction with this manual. All warnings and cautions must be observed.

DRYING OUT TIME

The refractory casing of the boiler is made from a material that uses a high proportion of water in the mixing process. Whilst some of the water is driven off by chemical reaction and the initial test firing, the refractory is still ‘wet’ when the boiler is delivered. For a 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 drying process.

3.2 BOILER CONTROLS

The following brief description of the controls used on the J series gas fired steam boiler is intended to provide the operator with a basic understanding of the operating principles, which is essential for the continued efficient operation of the boiler.

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 Relays and Feedwater 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.

Note: A set-back pressure controller is fitted when multi-boilers are fitted with a sequence control.

CONTINUED ON NEXT PAGE

JGASUK-IOMM-2015-2 Page 19 OPERATION - 3 Fulton Ltd

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 Multi-bloc gas valve will be closed.

Air Pressure Switch. Mounted on the burner scroll, this switch is operated by the pressure of air entering the burner through the throat of the scroll. Lack of air, or insufficient pressure, will prevent the switch completing the circuit thus preventing the burner from operating.

Gas Head Assembly. Consists of a Multi-bloc incorporating an integral governor, pressure switch and gas valves or for larger boilers in addition to the internal components, an external pilot line with its own gas solenoid valves and governor. For boilers fitted with fully modulating burners, a gas actuator is fitted to the gas train.

PUMP CONTROL Pump Interrupt/Pump Run Switch. Fitted on the left side of the control panel, used to override (switch off) the pump controls during evaporation tests.

Note: Boilers fitted on skid systems and in plantrooms are interlocked with the feedwater 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. This reset must also be selected after any electrical outage.

®

6J - 30J (non modulating burner)

®

40J - 60J (non modulating burner) (CPI indicator will be blanked)

®

40J - 60J (fully modulating burner)

Note: High Pressure button can be found on the side of the control box.

Figure. 18 - Control Panel Fascias

Page 20 JGASUK-IOMM-2015-2

PART N° 15184

® REF: ELECTRICAL ENCLOSURE 2009 FACIA LABEL Fulton Boiler Works, (Great Britain) Ltd PART: 15148 DRG: N° FD090051 METAL FACIA PLATE, DRG: N° FD090070 for GAS 'J' SERIES BOILER FD09 0071 Fulton Ltd OPERATION - 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:

! CAUTION 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 phases could be live. Always isolate the supply before investigating any fault.

Start/Low Water Reset. This switch is used to start 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 lock-out due to a low water condition. Once the water in the boiler has been restored to a safe operating level, pressing the switch will reset the controls.

Power On. Indicates that power is being supplied to the control panel box.

1st Low Water Alarm. 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 will sound.

2nd Low Water Reset. 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. Indicates that the ignition transformer has been energised. This light will only be illuminated for approximately 5 - 10 seconds during the ignition sequence.

Gas Pressure Alarm. This light will illuminate whenever the gas is off, or below minimum inlet pressure required by the European Standard for gas burners EN676. This switch is factory set and should not be adjusted after the boiler has been commissioned.

Start Gas. (40J - 60J models) This light indicates the gas valves in the pilot line are energised.

Main Gas. This light illuminates when the Multi-bloc gas valve is energised.

Flame Failure / Reset. This switch will be illuminated when the burner has gone to a lock out condition due to flame failure. The burner controller can be reset by pressing this switch.

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

ADDITIONAL INDICATOR LIGHTS ON MODELS 40J AND 60J NON MODULATING BURNER

Low Flame. This light indicates that the burner is operating in the low flame mode.

High Flame. This light indicates that the burner is operating in the full firing mode.

ADDITIONAL INDICATOR LIGHTS ON MODELS 40J to 60J FULLY MODULATING BURNER

High Pressure Reset. This switch will be illuminated when the boiler pressure exceeds the maximum allowable pressure. The high pressure controller can be reset by pressing this switch.

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3.4 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 the main steam stop valve is OPEN.

b) Ensure the steam pressure gauge isolating valve is OPEN.

c) Ensure all the valves in the main gas supply to the boiler are OPEN.

d) Ensure all the valves in the feedwater line are OPEN.

e) Ensure the main boiler blowdown valve is CLOSED.

f) Ensure the water level gauge (sight glass) isolating valve(s) is OPEN.

g) Ensure the water level gauge blowdown valve(s) is CLOSED.

h) Ensure the water column blowdown valve is CLOSED.

i) Ensure the Burner and Pump switch is in the OFF position.

j) Ensure all appropriate electrical isolators are switched ON.

k) Ensure the Pump Interrupt switch is switched OFF (Pump Run).

! CAUTION The feed pump seals are water cooled. The pump must never be allowed to run whilst dry, irreparable damage may result. Ensure the pump is fully primed before energising the motor.

l) Press the control switch to the PUMP ONLY position.

Note: If the boiler water level is below its correct level, the feedwater pump will operate. When the water reaches the correct level (two thirds up the water level gauge), the pump will stop. If the water level is above the top of the level gauge, drain off until the level is in the middle of the water level gauge (sight glass).

Page 22 JGASUK-IOMM-2015-2 Fulton Ltd OPERATION - 3

3.5 STARTING THE BURNER ALL MODELS

1. Press the control switch to PUMP AND BOILER position, the Low Water audible alarm will sound, the Low Water Reset and Low Water alarm lights will illuminate.

2. Press the Low Water Reset switch for two seconds maximum. The alarms will stop, and the alarm lights will extinguish.

The burner start sequence will commence.

3. After a maximum of one minute the burner should be firing, and the Main Gas light ON.

4. 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.

! 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:

a) Crack open the main steam valve and allow the system to heat up slowly (minimum 15 minutes) before fully opening the main steam valve.

b) Open the main steam valve when starting the boiler, allowing the boiler and system to heat up together.

Note: This can lead to water logging of the steam lines until full pressure is achieved. If fitted, TDS Panel Mounted Controllers (BC3150) must be reset after any break in electrical supply to the unit.

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Removing/replacing water level probe

Feedwater dip pipe

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. 19 - Boiler Maintenance

Page 24 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

SECTION 4 - MAINTENANCE

! CAUTION It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the daily, weekly, monthly and six monthly checks could result in a drastic reduction in the life expectancy of the boiler.

Tests should be carried out by a competent person trained to perform such tests. If any test shows that the equipment is not operating correctly, the fault should be investigated and corrected before the boiler is used.

Any rectification or repairs should be carried out by trained, competent service personnel.

4.1 VISUAL CHECKS

Inspect the steam and feedwater pipework, valves and fittings for signs of leakage. If leaks are suspected, shut down the system and evacuate the system to atmospheric pressure before attempting any repairs.

Note: 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.

4.2 WATER LEVEL AND LOW WATER SAFETY CONTROLS

The following procedures ensure the correct functioning of the water level controls and the low water safety controls.

4.2.1 PUMP TEST

a) If the boiler is not firing and not under steam pressure, lower the water level using the main blowdown valve:

If the pump is running:

1. Observe the water level in the water level gauge (sight glass).

2. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

If the pump is not running:

1. Check that the water level in the water level gauge is between Pump On and Pump Off levels. CONTINUED ON NEXT PAGE

JGASUK-IOMM-2015-2 Page 25 MAINTENANCE - 4 Fulton Ltd

2. Lower the water level by opening the main boiler blowdown valve.

3. Verify that the pump starts to run when the water level reaches the Pump On level.

4. Close the main boiler blowdown valve.

5. Continue to observe the water level in the water level gauge and verify that the pump continues to run until the Pump Off level is reached and then switches off.

b) If the boiler is firing and under load, lower the water level by evaporation, observing a pump cycle:

If the pump is running:

1. Observe the water level in the water level gauge.

2. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

If the pump is not running:

1. Check that the water level in the water level gauge is between Pump On and Pump Off levels.

2. The water level will lower through natural evaporation.

3. Verify that the pump starts to run when the water level reaches the Pump On level.

4. Continue to observe the water level in the water level gauge and verify that the pump continues to run until the Pump Off level is reached and then switches off.

4.2.2 1ST LOW WATER LEVEL CHECK

1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is between Pump On and Pump Off.

2. Switch off the pump using the Pump Interrupt/Pump Run switch.

3. Allow the water level to lower by natural evaporation below the 1st Low Water level.

4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the burner stops firing. Do not allow the water level to drop below the bottom of the water level gauge (sight glass).

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Switch on the pump using the Pump Interrupt/Pump Run switch.

6. Verify that the pump runs and refills the boiler. When the water level rises above the 1st Low Water level, verify that the Low Water lamp extinguishes, the Low Water audible alarm silences and the burner fire sequence starts.

7. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

Page 26 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.2.3 2ND LOW WATER LEVEL CHECK

1. Ensure that the boiler is firing, the feedwater pump is not running and that the water level is between Pump On and Pump Off.

2. Switch off the pump using the Pump Interrupt/Pump Run switch.

3. Allow the water level to lower by natural evaporation to the 1st Low Water level.

4. Verify that the Low Water lamp illuminates, the Low Water audible alarm sounds and that the burner stops firing. Do not allow the water level to drop below the bottom of the water level gauge (sight glass).

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Allow the water level to lower further by natural evaporation below the 2nd Low Water level. Do not allow the water level to drop below the bottom of the water level gauge.

6. Verify that the Low Water Reset switch illuminates.

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

7. Switch on the pump using the Pump Interrupt/Pump Run switch.

8. Verify that the pump runs and refills the boiler. When the water level rises above the 1st Low Water level, verify that the 1st Low Water lamp extinguishes but the burner fire sequence does not start.

9. Press the Low Water Reset switch- Verify that the 2nd Low Water lamp and audible alarm extinguishes and the burner starts.

10. Verify that the pump continues to run until the Pump Off level is reached and then switches off.

Figure. 20 - Pump Interrupt Switch

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4.3 MAIN BLOWDOWN

Keep the boiler, water level gauge (sight glass), water column and interconnecting pipework free from sludge and scale build-up by blowing down in the following manner:

Note: Where a boiler is operating continuously at steam pressure, advice should be sought from Fulton Service Department regarding the appropriate blowdown procedure.

1. Start the boiler and generate not more than 10 psi of steam (see note).

2. Shut off both the burner and the pump.

Boiler Blowdown

1. Fully OPEN the boiler main blowdown valve for not more than 5 seconds, or as recommended by the water treatment specialist.

2. CLOSE the valve.

Note: Where high levels of suspended solids are produced, longer and/or more frequent blowdown may be required. Figure. 21 - Main Boiler Blowdown Valve

4.4 WATER COLUMN BLOWDOWN

Note: The water column contains the pump ON/OFF probe, which is not safety interlocked.

1. Switch the pump off (pump interrupt) at the Pump Interrupt/Pump Run switch.

2. Open the water column blowdown valve for 5 seconds.

3. Close the water column blowdown valve and wait for 10 seconds for the boiler to refill and the water to stabilise in the vessel.

4. Switch the Pump Interrupt switch to Pump Run.

Figure. 22 - Water Column Blowdown Valve

Page 28 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.5 WATER LEVEL GAUGE BLOWDOWN

Blowdown the water level gauge (sight glass), set 1.

1. Open the water level gauge glass blowdown valve A

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

3. Open valve B

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

5. Open valve C

6. Close valve A

Repeat for gauge set 2

On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves are CLOSED.

Note: Where a boiler is operating continuously at steam pressure, advice should be taken from Fulton Ltd as to the appropriate blowdown procedure.

WORKING STEAM WATER POSITION BLOWDOWN BLOWDOWN

B B B

C C C

A A A

Operating Positions Figure. 23 - Water Level Gauge Operating Positions Figure. 24 - Water Level Gauges (sight glasses)

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4.6 EVAPORATION CHECKS

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

When the check is complete, proceed as follows:

c) Switch the pump ON at the pump interrupt/pump run switch.

d) Press the low water reset switch. The pump will start to refill the boiler.

If the pump starts to run at any time during the test then the test must be abandoned and restarted from the beginning.

4.7 FLAME SENSOR TEST

This test checks the operation of the flame safeguard sensor.

1. Ensure that the burner is firing.

2. Remove the flame sensor from its tube on the top of the burner.

3. Cover the sensor glass.

4. Verify that the burner goes out (the fan will run on for a short time but the flame should go out).

If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used.

5. Return the flame sensor to its tube on the top of the boiler.

6. Fire the burner to ensure correct operation.

Figure. 25 - Flame Sensor Removal

Page 30 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.8 DRAINING THE BOILER

! CAUTION Your local regulations could state boiler water above 43 °C must not be discharged into the drain. ALWAYS check your local regulations.

Boilers with manual blowdown valves

1. Ensure the boiler is cold.

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

3. Isolate the feedwater tank and the feedwater pump.

4. Open the main steam valve and the boiler drain valve.

5. Open the drain valve on the blowdown vessel.

6. Open all valves in the drain lines.

Boilers with automatic blowdown systems

1. The boiler should not be under pressure.

2. The boiler should be cold.

3. Close the blowdown isolation valve.

4. Using a screwdriver located as shown ‘A’, push up and make a quarter turn, this will lock the button in position and open the blowdown valve.

5. Using the blowdown isolation valve to throttle the flow, drain the boiler.

Note: Skid systems and plantrooms have internal drainage systems which require the same procedures.

A

Figure. 26 - Automatic Blowdown Valve

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4.9 LONG TERM SHUT DOWN

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

1. Fully flood the boiler to exclude as much air as possible.

2. Drain the boiler completely. Remove all hand hole and manhole doors. Open all gas/oil side access doors.

3. As (2) but also introduce a form of convection heating to the gas/oil and water side. A very effective solution is to install a string of outdoor type waterproof light bulbs distributed throughout the boiler.

4.10 INTERNAL INSPECTION

The lower hand hole doors should be removed after one month of operation and the interior of the boiler thoroughly examined. If scale or sludge build-up is observed, it should be removed and the water treatment supplier advised.

New gaskets must be fitted every time a hand hole door is removed. Subsequent interior examinations should be carried out on a regular basis until satisfactory conditions are observed. Thereafter, inspections should be carried out at three monthly intervals.

Hand Hole Cover Plate

Gasket

Crab

Figure. 27 - Hand Hole

Page 32 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.11 SCHEDULE OF OPERATOR TESTS AND CHECKS

The following schedule is the advice of Fulton Ltd. The frequency of tests and checks may vary according to site risk assessment and/or specific requirements of the country/territory that the boiler is installed in. Failure to maintain the boiler adequately may void the Fulton warranty.

Maintenance on gas related parts of a boiler must be carried out by competent, trained personnel who are GAS SAFE/ACS registered, and who have the necessary equipment to check combustion.

If any fault is found during these operations, contact your Fulton representative.

! 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.

Ensure any residual pressure within the boiler is completely vented before working on the pressure vessel.

! CAUTION It is essential that regular checks are made to ensure that scale build-up is not taking place within the boiler. Such checks will ensure that water treatment being applied to the boiler feedwater is effective.

Make sure that lifting equipment 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.

! IMPORTANT If any fault is found during these procedures, shut down the boiler immediately and consult Fulton Ltd.

The following procedures are designed to prevent the build-up of scale, silt or sludge in the bottom of the boiler, water level gauge (sight glass) and water column pipework. Personnel involved in doing this work must have received the appropriate training in all aspects of maintenance and safety procedures.

In addition to these procedures, the advice of a water treatment specialist should be sought and followed.

JGASUK-IOMM-2015-2 Page 33 MAINTENANCE - 4 Fulton Ltd

4.11.1 DAILY

1. Visually inspect the steam and feedwater 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.

2. Blowdown the Boiler (see Section 4.3).

Note: If the boiler is being operated automatically on a time clock, the blowdown may be done once during the working day and once at the end of the day when generating 10 psig or less, providing this is sufficient to control the TDS level within limits.

3. Blowdown the Water Column (see Section 4.4).

4. Blowdown the Water Level Gauge (sight glass), (see Section 4.5).

4.11.2 WEEKLY IN ADDITION

! WARNING Ensure the fittings around the steam safety valve(s) are secure. The safety valve will be very hot, do not operate the safety valve without protection.

5. Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe blowdown point.

6. Pump Test (see Section 4.2.1).

7. First Low Water Check (see Section 4.2.2).

8. Second Low Water Check (see Section 4.2.3).

9. Flame Sensor Test (see Section 4.7).

4.11.3 MONTHLY IN ADDITION

! WARNING Ensure the main electrical supply is isolated before starting work.

10. Visually inspect the internal water space (see Section 4.10).

11. Visually inspect the hand holes in the boiler. If any leakage is evident, the gasket needs replacing.

12. Visually inspect the flanged joint covering the rear inspection port in which the blowdown valve is fitted, if any leakage is evident, the gasket needs replacing.

13. Clean the water level gauges (sight glasses). If any leakage is evident, the gasket needs replacing.

14. Clean any water traps and strainers fitted in the feedwater line. Check feedwater and boiler water quality against the values given in Appendix A - TI-139- Recommended Water Conditions.

Note: Use only genuine Fulton replacement parts.

Page 34 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.11.4 THREE MONTHLY IN ADDITION

15. Drain and isolate the boiler.

16. Remove the lower hand hole assemblies and inspect the interior of the pressure vessel for scale and sludge build-up.

17. Remove the feedwater pipe from the top of the boiler. Ensure the pipe is not blocked, clean as required.

Figure. 28 - Feedwater Pipe Removal

4.11.5 SIX MONTHLY IN ADDITION

It should be noted that after a Fulton boiler has been in operation for several months, pieces of burned metal will be found in the space at the bottom of the boiler. These pieces of metal are the remains of a light gauge metal form which was used during manufacture for the forming of the boiler insulation. This is normal and does not affect the efficiency or the life of the boiler in any way.

18. 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 new gasket material and furnace cement to ensure a tight seal, subsequently preventing the escape of hot gases.

19. Apply a small quantity of oil to the bearings of the burner motor and the feedwater pump motor.

20. Drain and flush the feedwater tank. Clean any filters in the tank, in the feedwater line or in the feedwater pump.

21. Remove and clean the water level probes, take care not to crack the porcelain. After replacement of the probes, check the operation of the low water cut-off relay and of the feedwater pump.

22. Remove the air gate and clean the fan.

23. 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, there should be no smoke visible. If either of these tests fail, shut down the boiler and contact Fulton Ltd immediately.

24. Remove components from all threaded stub pipes, clean and inspect, replace if required.

CONTINUED ON NEXT PAGE

JGASUK-IOMM-2015-2 Page 35 MAINTENANCE - 4 Fulton Ltd

25. Remove the water level gauge (sight glass) and water column. Rod through the top connections of both to ensure that the holes in the baffle plates (approx. 6 mm dia.) inside the boiler are not obstructed.

26. Check the burner combustion to ensure that excess air and carbon monoxide values are within normal limits (see combustion values in Appendix A - TI-117-J Series Dimensions & Specification).

27. Check the condition of the gas valve filter (if fitted), renew as required.

Cleaning Remove cover the Flues plates and gasket

Remove the clean-out door to the flue passes and to the bottom of the boiler.

Oil boiler illustrated.

Figure. 29 - Flue Cleaning

Insulating rope

Refractory brick in place

Figure. 30 - Boiler Furnace Figure. 31 - Ignition Electrode

Page 36 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

Figure. 32 - Burner Plate Figure. 33 - Burner Assembly

4.11.6 ANNUALLY IN ADDITION

28. Fulton Ltd recommend replacement of all threaded stub pipes on the boiler OR to your inspectors satisfaction.

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4.12.1 TROUBLESHOOTING BOILER

Problem Cause Remedy Ignition Failure 1. Power Supply Check fuse or circuit breaker. Reset or Replace as required. 2. Ignition Electrodes Check for cracks in porcelain,if found replace the electrode. Check electrodes for carbon build-up. Clean as required. Check settings, adjust if required. 3. Transformer Check voltage between transformer leads at terminal block to be sure transformer is live. 4. Burner Control Check voltage between ignition terminal and neutral, this check must be made before the control locks out. If no power, replace the control. 5. Air Settings Check main air adjustment and secondary air adjustment. 6. Faulty Air Switch Check for faulty air switch. 7. Gas Valve Check filters in the valve block. Clean as required. 8. Gas supply Check for gas pressure and intermittent supply problems. 9. Loose wire connections Check connections to all components. Flame Failure During 1. Power Supply Check fuse or circuit breaker. Start-up Reset or replace as required. 2. Gas supply Check for gas pressure and intermittent supply problems. 3. Air Settings Check main air adjustment and secondary air adjustment. 4. Ignition Electrodes Check electrodes for carbon build-up. Clean as required. Check for proper adjustment, readjust if necessary. Check for cracks in porcelain, if found replace the electrode. 5. UV Detector Check the detector is located correctly and clean. 6. Burner Control Check voltage between ignition terminal and neutral, this check must be made before the control locks out. If no power, replace the control. 7. Loose wire at fuel valve Tighten wiring connections. circuit. 8. Contact open on Air Switch Adjust to the correct setting. 9. UV Detector wiring reversed Change to the correct terminals. at control box. Flame Failure During 1. Power Supply Check fuse or circuit, reset or replace as necessary. Normal Run 2. Gas Supply Check gas pressure coming into the gas train, if low contact the gas supplier. Check the setting on the gas valve regulator, adjust as required. 3. UV Detector Check the detector is located correctly and clean. 4. Faulty Air Switch Check for faulty air switch. 5. Bad Combustion Check combustion readings.

CONTINUED ON NEXT PAGE

Page 38 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.12.1 TROUBLESHOOTING BOILER

Problem Cause Remedy Burner Cut-off 1. Gas Valve Check filters in the valve block. Clean as required. 2. Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator. 3. Faulty Level Control Test level controls, adjust or replace as required. 4. Dirty or defective UV detector Clean or replace. Poor Combustion 1. Refractory Bricks Check refractories to see if they are blocked with soot or broken in pieces. Clean or replace as necessary. 2. Stainless Steel Ring Check the ring is present (40J - 60J models) and fits tightly against the furnace wall. 3. Main Air Adjustment Check air adjustment. Air/fuel mixture may be off. Open main air gate until the flame brushes the furnace wall. 4. Secondary Air Adjustment Check main air adjustment, reset as required and secure in place.

Check CO2 and O2 levels. 5. Draft Check draft with a gauge. Readings will vary between installations, if in doubt consult Fulton for a draft value for your system. 6. Dirty Flue Check flue for carbon build-up or blockage. Clean the flue. 7. Negative Room Pressure Ensure there are no exhaust fans running in the boiler room. 8. Dirty Fan Check fan for obstructions, clean as required. Burner Back Fires 1. Refractory Bricks Check refractories to see if they are plugged with soot (Delayed Ignition) or broken in pieces. Clean or replace as necessary. 2. Ignition Electrodes Check electrodes for carbon build-up. Clean as required. Check for proper adjustment, readjust if necessary. Check for cracks in porcelain, if found replace the electrode. 3. UV Detector Check the detector is located correctly and clean. 4. Draft Check draft with a gauge. Draft should be -.05 to -.10 mbar with the burner off, or -.10 to -.15 mbar when operating. A barometric damper may need to be installed. 5. Negative Room Pressure Ensure there are no exhaust fans running in the boiler room. 6. Air Adjustment Check Air Adjustment settings. 7. Gas Supply Check gas pressure coming into the gas train, if low contact the gas supplier. Check the setting on the gas valve regulator, adjust as required.

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JGASUK-IOMM-2015-2 Page 39 MAINTENANCE - 4 Fulton Ltd

4.12.1 TROUBLESHOOTING BOILER

Problem Cause Remedy Boiler will 1. Gas Supply Check gas pressure coming into the gas train, if low not maintain contact the gas supplier. pressure Check the setting on the gas valve regulator, adjust as required. If possible meter the flow rate. 2. Dirty Flue Check flue for carbon build-up or blockage. Clean the flue. 3. Pressure Control Disconnect all power to the controller. Disconnect the wires from the controller. Place an OHM meter between the switch terminals. Lower the set point of the controller, the switch should make. Raise the set point and recheck, the switch should break. If the controller operates improperly, replace it. 4. Scale build-up in boiler Clean the pressure vessel. 5. Refractory Bricks. Check refractories to see if they are blocked with soot or broken in pieces. Clean or replace as necessary. 6. Steam traps blowing through. Check steam traps, clean or replace as required. 7. Boiler size. Boiler may be undersized. 8. Faulty Gas Valve. Check gas flow rate. Boiler is 1. Steam traps blowing through. Check steam traps, clean or replace as required. Surging (Widely 2. Contamination in boiler. Empty boiler and feed tank. fluctuating water Flush out and refill, if system operates but level in sight progressively deteriorates, there is probably a leak glass) somewhere in the system. 3. Scale buildup or lime deposits. Consult Fulton or call a water treatment specialist. 4. Too much compound (water Dump contents of the return tank and flush the treatment over dose). system. Test the water. 5. High Alkalinity (high pH). Have a water treatment specialist test the water. 6. Load exceeds boiler capacity. Check total system load against the output of the boiler. Decrease the load required at any one time. Boiler rumbles 1. Poor Combustion Check combustion readings. and pulsates 2. Draft. Check draft with a gauge. Draft should be -.05 to -.1 mbar with the burner off. A barometric damper may need to be installed. 3. Too much main air. Adjust main air gate. Boiler carrying 1. Steam Traps. Check steam traps, clean or replace as required. over water with 2. Too much compound (water Dump contents of the return tank and flush the the steam treatment over dose) in the system. system. Test the water. system. 3. Contamination in boiler. Empty boiler and feed tank. Flush out and refill, if system operates but progressively deteriorates, there is probably a leak somewhere in the system.

Page 40 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.12.2 TROUBLESHOOTING FEEDWATER PUMP

Problem Cause Remedy FEEDWATER PUMP 1. Supply failure. Connect the electricity supply. Pump will not run 2. Fuses/Circuit Breakers are blown. Replace fuses/Circuit Breakers. 3. Motor contactor overload has Reactivate the motor protection. tripped out. 4. Contactors not making Check, the coil is faulty or wiring loose. 5. Control circuit is defective. Repair the control circuit. 6. Motor is defective. Replace the motor. Motor starter overload, 1. One fuse/automatic circuit breaker is Replace the fuse, reset the circuit trips out immediately blown. breaker. when supply is 2. Contacts in motor contactor overload Replace motor starter contacts. switched on. are faulty. 3. Cable connection is loose or faulty. Tighten or replace the cable connection. 4. Motor winding is defective. Replace the motor. 5. Pump blocked. Remove the blockage. 6. Overload setting too low. Set the motor starter correctly. Motor contactor 1. Overload setting is too low. Set the overload correctly. overload trips out 2. Low voltage at peak times. Check the electricity supply. occasionally. Motor contactor has Check : not tripped out but the Motor does not run when started: pump does not run. items: 1, 2, 4, 5, 6, Pump capacity not 1. Pump inlet pressure is too low Check the suction conditions. constant. (cavitation). 2. Suction pipe/pump partly blocked. Clean the pump or suction pipe. 3. Pump draws in air. Check the suction conditions. Pump runs but gives 1. Suction pipe/pump blocked. Clean the pump or suction pipe. no water. 2. Foot or non-return valve blocked in Repair the foot or non-return valve. closed position. 3. Leakage in suction pipe. Repair the suction pipe. 4. Air in suction pipe or pump. Check the suction conditions. 5. Pump rotates in the wrong direction. Change the direction of rotation of the motor. 6. Boiler feedwater non-return valve Check and clean boiler feedwater letting water passed the valve seat, non-return valve, ensure it is seating (normally and not allowing water passed. accompanied by banging in the feedwater tank).

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JGASUK-IOMM-2015-2 Page 41 MAINTENANCE - 4 Fulton Ltd

4.12.2 TROUBLESHOOTING FEEDWATER PUMP

Problem Cause Remedy Pump runs 1. Leakage in suction pipe. Repair the suction pipe. backwards when 2. Foot or non-return valve is Repair the foot or non-return valve. switched off. defective. Leakage in shaft seal. 1. Shaft seal is defective. Replace the shaft seal. Noise. 1. Cavitation occurs in the Check the suction conditions. pump. 2. Pump does not rotate Adjust the pump shaft. freely (frictional resistance because of incorrect pump shaft position. 3. Frequency converter See Grundfos manual. operation. 4. Boiler feedwater non-return Check and clean boiler feedwater non-return valve, valve letting water passed ensure it is seating and not allowing water passed. the valve seat, (normally accompanied by banging in the feedwater tank). Water pump will 1. Scale on probes. Check and clean probes, replace as not come on at necessary. times. 2. Faulty pump contactor Check the contactor has power. Check the contactor is pulling in. Replace if necessary. 3. Faulty pump motor. Check the pump has power. If the pump has power but is not running, replace it. 4. Faulty Level Control Relay Check the relay has power and is secure on it’s base. Replace if faulty. Low fuel pressure. 1. Gas pressure regulator Check and replace. Boiler flooding 1. Pump does not shut off. Dirty probes. Clean or replace as necessary. 2. Relay failed. Ensure the relay is secure on its base. If so replace the water level relay. 3. Earth connection. Clean and tighten as required. 4. Vacuum created with boiler As the boiler cools, it pulls water from the system off. piping. To prevent this, add a check valve on the steam gauge assembly piping, which closes under pressure and opens under vacuum.

Page 42 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.12.3 TROUBLESHOOTING BURNER CONTROL UNIT-LFL 1 (SIEMENS)

Symptom and Cause Remedy identification symbol No Start 1. No Power Check all fuses/circuit breakers Check for correct wiring. 2. External Interlocks Check all external interlocks are made. 3. Air Pressure Switch Check that the switch is in ‘No Air’ position. 4. CPI switch If fitted, must be made. 5. Air Damper If fully closing damper fitted, check relevant micro switch on damper. 6. Burner Motor fault Check overload. Lockout 1. False flame detected Check for stray light (cell only). Faulty cell or damaged flame probe. Interruption of 1. Air Damper Check fully open microswitch is made. start-up sequence

Lockout 1. Air Pressure Switch Check that switch is made. 2. Note: Any air pressure P failure after this time will cause a lockout condition. Lockout 3. Flame supervision Check for stray light (cell only). Faulty cell or damaged flame probe. Interruption of 1. Air Damper Check low fire microswitch is made. start-up sequence

Lockout 1. No ignition spark Check supply ignitor. Check electrode and HT leads for damage. 2. No pilot flame Check gas supply. Check electrode setting. 1 Check functionality of pilot gas valve(s). Check pressure gas downstream of pilot valve(s). 3. Pilot lights then extinguishes Check flame stability with ignition off. Note: Any flame signal Check air pressure at burner. failure after this stage will Check gas pressure is steady. cause a lockout condition Check the flame is being sensed, i.e. (i) Check sensor for damage. (ii) Check sensor can view flame. (iii) Check flame signal, see data sht. LFL1 - 7451

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JGASUK-IOMM-2015-2 Page 43 MAINTENANCE - 4 Fulton Ltd

4.12.3 TROUBLESHOOTING BURNER CONTROL UNIT-LFL 1 (SIEMENS)

Symptom and Cause Remedy identification symbol Lockout 1. No main flame Check supply to main valve(s) Check functionality of main valve(s). Check gas pressure at burner. 2 Check air pressure at burner. Check flame signal strength, refer to LFL1 data sht. 7451 Lockout 1. Flame failure Check flame signal. 2. Air pressure failure Check switch operation. l Lockout on 1. Extraneous light Check flame extinguished. completion of control Check gas valves for leaks. programme sequence 2. Faulty flame signal Check for aged/faulty UV cell. Check flame supervision circuit.

Page 44 JGASUK-IOMM-2015-2 Fulton Ltd MAINTENANCE - 4

4.13 MAINTENANCE LOG

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

Date Action Remarks Sig.

JGASUK-IOMM-2015-2 Page 45 MAINTENANCE - 4 Fulton Ltd Y - N Y - N Y - N sig. sig. sig. sig. Burner cut-out alarm sound Burner cut-out and alarm sound Self Monitoring Controls (if fitted) Level First Low Water *11. Level *12. Second Low Water Boiler Number: *13. Pressure gauge reading. Note: *Additional tests to be completed on the 7th day *10. Flame failure device tested. 7 Y - N Y - N Y - N Y - N 6 Y - N Y - N Y - N Y - N 5 Y - N Y - N Y - N Y - N 4 5. 6. 7. 7+. Date: Day Y - N Y - N Y - N Y - N Day 3 Y - N Y - N Y - N Y - N 2 Y - N Y - N Y - N Y - N 1 Y - N Y - N Y - N Y - N Date sig. sig. sig. sig. reading reading reading PH TDS. leakage

of

Fuel:

signs

Duration seconds. Duration seconds. Duration seconds. Test Time. Test Test Time. Test Time. Test for

fittings

and

, Burner cut-out alarm sound. datum value. datum value. datum value. Model: Vertical Steam Boiler - Daily and Weekly Tests Steam Boiler - Daily and Weekly Vertical pipework

of

1. 2. 3. 4. Visual Inspection Visual Pump Check , Feed pump, start/stop Level , Burner cut-out and alarm sound First Low Water Level Second Low Water Blowdown, Boiler Column Blowdown, Water Level Gauge Blowdown, Water Boiler Water. Treatment. Water Pressure gauge reading for blowdown tests. Boiler water and treatment values must be within known tolerances of the datum.

Log examined by: Operator Signature: 1. 2. 3. 4. 5. 6. 7. 8. 9. Day Test Results and actions taken Test

Page 46 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - A

APPENDIX A - TI SHEETS

The Fulton boiler manual refers to a number of Fulton TI sheets. These TI sheets can be found in this Appendix.

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

JGASUK-IOMM-2015-2 Page 47 APPENDIX - A Fulton Ltd

Page 48 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - A

Technical Information Sheet No. 117 Issue 8 J Series Dimensions & Specification

Dimensions

H

R

V 360°

G A K C W L J U M D X T E N P B S

MODEL: J SERIES 6J/8J/10J 15J 20J 30J 50J/60J A Minimum Clearance* 2300 2400 2600 2800 3100 B Overall Width 980 1030 1250 1440 1655 C Overall Depth 1025 1060 1400 1595 1850 D Overall Height 1745 1835 1990 2170 2440 E Boiler Height 1670 1760 1890 2070 2320 F Boiler Diameter 715 765 985 1175 1390 G Height to Top of Fan 1810 1900 2030 2210 2460 H Gas Train Length 425 555 555 570 940 J Gas Inlet Height 2045 2165 2330 2510 2820 K Oil Inlet Height 1550 1640 1735 1915 2150 L Safety Valve Discharge Height 1840 1930 2060 2240 2490 M Steam Outlet Height 1845 1950 2100 2310 2680 N Feedwater Inlet Height 1810 1900 2030 2210 2460 P Flue Outlet Height 1500 1565 1670 1820 2075 R Flue Diameter 152 203 255 305 305 S Main Boiler Blowdown Height 380 380 390 390 395 T Control Column Blowdown Height 1025 1115 1245 1385 1670 Water Level Gauge (Sight Glass) U 1060 1155 1285 1465 1710 Blowdown Height V Water Level Gauge Stand Off 265 265 265 265 265 W Control Column Stand Off 270 270 270 270 265 X Fan Stand Off 330 330 440 480 500

* Recommended height for service & maintenance

Note: Dimensions mm Note: Dimensions are approximate and only intended as a guide to aid installation.

Page 1 of 2

JGASUK-IOMM-2015-2 Page 49 APPENDIX - A Fulton Ltd

Specification TI-117-J-DS-2015-8

MODEL: J SERIES UNIT 6J 8J 10J 15J 20J 30J 50J 60J CE marked to PED, EMC & LVD, constructed to BS2790 as standard (other code specifications available).

General Steam Output F & A 100 °C kg/h 96 128 160 240 320 480 800 960 kW Rating kW 60 80 100 150 200 300 500 600 Operating Pressure ** barg 10.34 10.34 10.34 10.34 10.34 10.34 10.34 10.34 Weight Shipping Weight kg 977 977 977 1090 1620 2270 3400 3400 Operational Weight kg 1067 1067 1067 1290 1910 2910 4420 4420 Water Content L 90 90 90 200 290 640 1020 1020 Efficiencies Gross % 80 80 80 80 80 80 80 80 Net % 89 89 89 89 89 89 89 89 Gas Pressures Min. Natural Gas Modulating*** mbar - - - - - 30 30 30 Min. Natural Gas On/Off mbar 18 18 18 18 18 18 18 18 Max. Natural Gas mbar 100 100 100 100 100 100 100 100 Min. LPG mbar 50 50 50 50 50 50 50 50 Max. LPG mbar 80 80 80 80 80 80 80 80 Firing Rate Gas **** m3/h 7.0 9.3 11.6 17.4 23.2 34.8 58.1 69.6 Oil L/h 7.1 9.4 11.8 17.6 23.6 35.2 58.9 70.4 LPG/Propane m3/h 2.9 3.9 4.8 7.2 9.6 14.4 24.1 28.9 Ventilation Requirements for Combustion Purposes (Free Area) Low Level inlet cm2 670 800 920 1250 1570 2220 3530 4170 High Level Outlet cm2 335 400 460 625 785 1110 1765 2085 Electrical Requirements FLC 400 V 3 ph 50 Hz A/ph 4.7 4.7 4.7 4.7 4.9 4.9 6.9 6.9 FLC 230 V 1 ph 50 Hz A 12.7 12.7 12.7 12.7 14.9 --- Connection Sizes All threads BSP F= Female, M=Male Steam Outlet DN 20 F 20 F 25 F 32 F 32 F 40 F 50 F 50 F Safety Valve Discharge DN 25 F 25 F 25 F 25 F 25 F 25 F 32 F 32 F Feedwater Inlet DN 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F Feedwater Pump Inlet DN 25 F 25 F 25 F 25 F 25 F 25 F 25 F 25 F Blowdown, Boiler DN 20 F 20 F 20 F 20 F 25 F 25 F 25 F 25 F Blowdown, Water Column DN 20 F 20 F 20 F 20 F 20 F 20 F 20 F 20 F Blowdown, Water Level Gauge DN 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F (Sight Glass) Blowdown, TDS DN 15 F 15 F 15 F 15 F 15 F 15 F 15 F 15 F Water Sample Outlet DN 15 M 15 M 15 M 15 M 15 M 15 M 15 M 15 M Flue Outlet in. 6 6 6 8 10 12 12 12 Gas Inlet DN 20 F 20 F 20 F 32 F 32 F 40 F 50 F 50 F Oil Connection in. Flexible hoses provided 1/4 in. BSP all models. ** Boilers at higher pressure, available to special order. *** Modulating control available at lower gas pressures, to special order. **** Natural Gas - Group H.

Page 2 of 2

Telephone: +44 (0) 117 972 3322 Fulton Ltd Fax: +44 (0) 117 972 3358 5 Fernhurst Road, Fishponds, Bristol. E-mail: [email protected]

BS5 7FG. England. Website: www.fulton.co.uk 003 FMFM 2840028400 Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

Page 50 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - A

Technical Information Sheet No. 137 Issue 1 J Series Probe Lengths

DATUM: underside of probe hex.head Top of Sockets / Shell / Furnace 216 430 405 216 Centre 241 Pump Off Pump On High Water Probe High Water of 2nd Low Water 1st Low Water Glass

1st Low Water

2nd Low Water Note: ‘350’ Sight Glass

Probe Lengths Probe Lengths High Level 216 Pump Off 216 1st Low Water 405 Pump On 241 2ndProbe Low Water Lengths 430 - J Series measurements in mm Pump OFF 216 Pump ON 241 1st Low Water 405 2nd Low Water 430 High Water 216

Note: Dimensions mm Note: Dimensions are approximate and only intended as a guide to aid installation.

Telephone: +44 (0) 117 972 3322 Fulton Ltd Fax: +44 (0) 117 972 3358 5 Fernhurst Road, Fishponds, Bristol. E-mail: [email protected] BS5 7FG. England. Website: www.fulton.co.uk 003 FMFM 28400 28400 Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

JGASUK-IOMM-2015-2 Page 51 APPENDIX - A Fulton Ltd

Page 52 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - A

Technical Information Sheet No. 139 Issue 1 J Series & Electric Steam Boilers Recommended Water Conditions

! IMPORTANT

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 for boiler water

FEEDWATER (water entering boiler) pH Value 8.5 to 9.5 tested at room temperature.

Hardness Less than 2.0 mg/kg in the form of CaCO3. Suspended Solids None Chloride Less than 50 mg/kg. Organic Matter Less than 5 mg/kg. Oil None Minimum Temperature 85 °C BOILER WATER (water inside boiler) pH Value 9.5 to 11.5 tested at room temperature. Hardness Not detectable. Suspended Solids Less than 100 mg/kg. Chloride Less than 500 mg/kg. Oxygen Scavenger, Sodium Sulphite or Tannin 20 to 50 mg/kg.

Phosphate Less than 50 mg/kg, in the form of PO4. Total Alkalinity Less than 1000 mg/kg.

Caustic Alkalinity Less than 300 mg/kg as CaCO3. Total Dissolved Solids (TDS) Less than 2000ppm. Iron Less than 1 mg/kg.

Silica Less than 150 mg/kg, in the form of SiO2. Dissolved Oxygen None

KEY mg/kg = Milligrams per Kilogram It is critical that the boiler water pH be alkaline in the range 9.5 - 11.5. CaCO3 = Calcium Carbonate

PO4 = Phosphate Daily boiler blowdown is essential to help prevent formation of deposits SiO2 = Silicon Dioxide and reduce Total Dissolved Solids PPM = Parts Per Million (TDS).

1 Grain hardness = 17.118 ppm Consult your water treatment specialist to establish the frequency and duration therefore 70 ppm = 4.10 grains hardness of blowdown required to achieve the required conditions. For practical = ppm purposes mg/kg

Telephone: +44 (0) 117 972 3322 Fulton Ltd Fax: +44 (0) 117 972 3358 5 Fernhurst Road, Fishponds, Bristol. E-mail: [email protected]

BS5 7FG. England. Website: www.fulton.co.uk 003 FMFM 2840028400 Every effort is made to ensure accuracy at time of going to press. However as part of our policy of continual product improvement, we reserve the right to alter specifications without prior notice.

JGASUK-IOMM-2015-2 Page 53 Fulton Ltd

Page 54 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - B

APPENDIX B - WATER LEVEL PROBE INFO

! IMPORTANT Terminal and securing nuts must not be adjusted.

Only Angle Rajah are to be used to connect wire to the probes.

The Terminal & Securing Nuts are tightened to a specified torque during manufacture which causes the PTFE Insulation to seal against the probe body. Therefore these nuts must not be adjusted because the seal will be broken which may cause the probe to leak (see Figure. 34).

Angle Rajah ONLY must be used to connect wire to the probes because they clip directly to the Terminal Nut. Spade Connectors must NOT be used because the Terminal Nut would require adjustment and therefore cause the probe to leak (see Figure. 35).

N.B. The Probe Rod Grub Screw and Lock Nut are suitably tightened during manufacture, meaning the probe is ready to be installed without any adjustment.

The ONLY instance a spanner should be used, is to turn the Probe Body in order to remove or reinstall the entire probe.

Terminal nut Securing nuts

Probe wire

Probe body Angle rajah

Terminal nut PTFE Insulation Probe rod grub screw Probe body Probe rod Probe rod lock nut

Figure. 34 - Water Level Probe Components Figure. 35 - Angle Rajah Fitted to Probe

JGASUK-IOMM-2015-2 Page 55 Fulton Ltd

Page 56 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - C

APPENDIX C - MOTORISED HIGH/LOW CONTROL

1.1 GENERAL

The Fulton motorised high/low control is designed to improve the efficiency of the boiler by switching the firing rate from high fire (when there is low steam pressure in the boiler) to low fire (when the boiler reaches a high steam pressure). The systems major components comprises of; two stage gas valves, motorised air damper unit and two stage steam pressure switches.

! IMPORTANT The adjustment of the air gate control motor or the two stage gas valve should only be carried out by qualified personnel, incorrect adjustment could result in damage to the pressure vessel and/or the production of harmful combustion gases.

Air Damper Housing

High/Low Fire Cams

Air Damper Motor

Figure. 36 - High/Low Control

1.2 OPERATION

With the steam pressure switch pre-set to the high and low fire operational requirements of the system, and the boiler operating normally, steam pressure will gradually increase until the high pressure limit is reached, the pressure switch will then switch the two stage gas valve and the air damper motor to the low fire position.

The boiler will continue to operate at low fire until the steam pressure falls to the low pressure limit setting on the pressure switch. At this point, the gas valve and the air damper will switch the boiler into high fire mode and the sequence of high fire / low fire is regulated automatically with no routine maintenance required.

Note: Should the boiler attain the off setting of the on/off control pressure switch, the burner will switch off on low fire and then restart in the normal way on high fire.

JGASUK-IOMM-2015-2 Page 57 APPENDIX - C Fulton Ltd

1.3 ADDITIONAL CONTROLS

Low Fire Hold Switch - Used to maintain the boiler in the low fire mode during commissioning.

1.4 COMMISSIONING

Commissioning should be carried out by a qualified Fulton Service Engineer.

To achieve the ideal combustion efficiency and gas input rates, a gas flow rate meter is required to measure the fuel input to the boiler.

1.4.1 FUEL INPUT RATES

Model 6 8 10 15 20 30 40 50 60 Low Fire m3/h 3.5 4.7 5.8 8.7 11.6 11.6 23.2 29.0 34.8 ft3/min. 2.1 2.8 3.4 5.1 6.9 10.3 13.7 17.1 20.5 High Fire m3/h 7.0 9.3 11.6 17.4 23.2 34.8 46.4 58.1 69.6 ft3/min. 4.1 5.5 6.8 10.2 13.7 20.5 27.3 34.2 41.0

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

1.4.2 AIR DAMPER MOTOR - FACTORY CAM SETTINGS

Blue cam N7 not used Red cam N6 Red cam N5 Red cam N4 not used Red cam N3 not used Yellow cam N2 Yellow cam N1

Terminal Position Degrees N1 High Fire Motor Cam 45° N2 Low Fire Motor Cam 10° N5 High Fire Interlock Cam 40° N6 Low Fire Interlock Cam 15°

Figure. 37 - Air Damper Motor

Note: The high fire interlock cam should always be set approximately 5° lower than the high fire cam position. The low fire interlock cam should always be set approximately 5° higher than the low fire cam position.

Page 58 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - C

1.4.3 SETUP PROCEDURE

1. Set the cams on the air damper motor to the initial position. Start the boiler and wait until the motor and gas valve have driven to high fire. Adjust the main (primary) air gate to achieve the best combustion with the least buffeting in the furnace.

2. Using the low fire hold switch, hold the boiler in low fire. The air damper motor should move to its low fire position and the high fire light on the control panel should extinguish, indicating the gas and air input rates have been reduced to approximately half the high fire input rate.

Note: If gas flow rate equipment is available, the low fire gas input rate should be adjusted to the correct value (see fuel input rates table) by rotating the black 1st stage partial adjustment ring located below the 2nd stage solenoid.

3. The ideal low fire CO2 constituent of the flue gases is 8 - 10.5%. Place an exhaust gas analyser into the flue, reduce or increase the amount of air entering the boiler as required, by adjusting the low fire cam (N2) position.

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

Reduced air: adjust the cam to reduce the amount of air entering the boiler, the reaction of the motor will be immediate.

Increased air: adjust the cam to increase the amount of air entering the boiler, switch the low fire hold switch off. When the motor has driven back to high fire turn the low fire hold switch on, the

damper will drive back to its new low fire position. Adjust the cams until the correct CO2 figure is achieved.

Note: Any adjustment to the cam positions requires an adjustment to its interlock cam position.

4. Switch off the low fire hold switch.

Note: if gas flow rate equipment is available, the high fire gas input rate can now be set (see fuel input rates table) by adjusting the pressure control screw located under a protective cover on the black electrical connection block.

5. The high fire CO2 constituent of the flue gases is 10 - 10.5%. Place an exhaust gas analyses into the flue, reduce or increase the amount of air entering the boiler as required, by adjusting the high fire cam (N1) position. To reduce the amount of high fire air, the damper will have to be driven to its low fire position and back again, before it takes up its new position. Ensure that the high fire interlock cam N5 is always set approximately 5° below the high fire motor position cam N1. Record all cam settings and the high and low fire final gas elbow pressures for future reference.

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

1.5 SPARE PARTS

Part No. Description Qty Model 13195 Transformer, ZT931 1 40 - 60 11643 Switch, air pressure 1 40 - 60 14485 Motor, damper, A30 045Y 1 40 - 60 12075 Fan 1 40 - 60 14489 Coupling, air gate 1 40 - 60

JGASUK-IOMM-2015-2 Page 59 Fulton Ltd

Page 60 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - D

APPENDIX D - SPIRAX HIGH INTEGRITY LEVEL CONTROLS

1.1 DAILY TESTS

The daily testing of boiler water level controls is a mandatory requirement as defined in the Health & Safety Executive Guidance Note BG01, Arrangements 2 and 3. 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 daily by a qualified boiler attendant, but may be supervised during the silent hours and weekends by a competent person trained to respond to an alarm.

Daily testing of the controls is required which can be by simulation, with a weekly test by interrupting the feedwater pump and lowering the water by evaporation.

1.1.1 1ST LOW WATER DAILY

1. Press and hold the 1st Low Water test button 5 - 6 seconds, the Low Water alarm sounds, and the Low Water indicator lamp illuminates, and the burner shuts down.

2. Release the test button.

3. After approximately 17 seconds the Low Water alarm will cancel, the Low Water lamp will extinguish, and the burner will restart.

1.1.2 2ND LOW WATER DAILY

With the burner firing:

1. Press and hold the 2nd Low Water test button for 5 - 6 seconds, the Low Water alarm sounds, and the 2nd Low Water Reset switch illuminates, and the burner shuts down.

2. Release the test button.

3. After approximately 17 seconds the 2nd Low Water Relay will reset.

4. To cancel the 2nd Low Water level alarm and light, depress the 2nd Low Water Reset switch.

The burner will restart.

JGASUK-IOMM-2015-2 Page 61 APPENDIX - D Fulton Ltd

1.2 WEEKLY TEST IN ADDITION

1.2.1 1ST LOW WATER WEEKLY IN ADDITION

With the burner firing:

1. Switch the Pump Interrupt switch to the Pump Interrupt position.

2. By evaporation lower the water level in the boiler until the 1st Low Water alarm sounds and the Low Water indicator lamp illuminates, and the burner shuts down.

3. Switch the Pump Interrupt switch to the Pump On position.

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

5. After approximately 17 seconds from restoring the 1st Low Water level the Low Water alarm will cancel, the Low Water lamp will extinguish, and the burner will restart.

1.2.2 2ND LOW WATER WEEKLY IN ADDITION

With the burner firing:

1. Switch the Pump Interrupt switch to the Pump Interrupt position

2. By evaporation lower the water level in the boiler until the Low Water alarm sounds, the 2nd Low Water Reset switch illuminates, and the burner shuts down.

3. Switch the Pump Interrupt switch to the Pump On position.

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

5. After approximately 17 seconds from restoring the 2nd Low Water level the 2nd Low Water Relay can be reset.

6. To cancel the 2nd Low Water Level alarm and light, depress the 2nd Low Water 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 2nd Low Water alarm will occur immediately after the burner has shut down on 1st Low Water, without the apparent loss of any more water. The reason is the collapse of the steam bubbles at the water level surface when the heat is removed. The degree of collapse could be such that the water level will disappear from the bottom of the sight glass before the alarm sounds. Should this happen, the 2nd Low Water Level alarm should be checked by lowering the water level slowly by partially opening the main blowdown valve.

Figure. 38 - Pump Interrupt Switch

Page 62 JGASUK-IOMM-2015-2 Fulton Ltd APPENDIX - E

APPENDIX E - AUTOMATIC TDS BLOWDOWN SYSTEM

1.1 GENERAL

The purpose of an Automatic, Total Dissolved Solids (TDS) Control Blowdown System, is to control the TDS level within the boiler around a set point. It is not a substitute for the main boiler blowdown, which must be used to control suspended solids, and prevent the build-up of sludge in the bottom of the boiler. The daily testing of boiler water level controls is a mandatory requirement as defined in the Health & Safety Executive Guidance Note BG01, Arrangement 3.

The method of operation is to take a sample of the boiler water at pre-set timed intervals, pass the sample over an electrode which measures water conductivity (which is proportional to TDS for a given water chemistry), and then compares the result with the control value (normally 2000 ppm), which is set when the unit is commissioned.

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

For the system to function reliably, the control must be calibrated to a typical water sample that is representative of the water conditions that are likely to prevail during normal running of the boiler and system. Conductivity and as a consequence TDS, can vary significantly with water chemistry. Changes in condensate return rates, alkalinity, chemical dosage, and suspended solids can all affect the performance of an Automatic TDS Blowdown System.

Condensate return rates that vary greatly on a day to day basis can severely disrupt the reliability of the conductivity measurement.

e.g. A boiler with a 50% condensate return and a raw water TDS of 400 will have a boiler feed water TDS of 200 ppm. Figure. 39 - TDS Graph 1

JGASUK-IOMM-2015-2 Page 63 APPENDIX - E Fulton Ltd

Systems that return for example very little condensate during the day, but a high proportion at night, are almost impossible to control with any real accuracy. At best a compromise calibration will be achieved, where too much blowdown at times may be the penalty.

When installing and commissioning a new Automatic TDS Control Blowdown System, it must be accepted that the calibration will be a reiterative process, requiring continual sampling, testing, and re-calibration until stable system operating conditions are achieved.

When purchasing an Automatic TDS Control Blowdown System from Fulton, the equipment would normally be supplied with the controller wired and fitted to the boiler control panel, with all the other parts supplied loose for piping and wiring on site by others, unless agreed otherwise in our order acknowledgement.

Further re-calibration will be required until the water treatment regime has been established, and “typical” water conditions have been achieved. Routine calibration checks will be required as part of the site maintenance and water treatment monitoring.

The equipment, staff training required to carry out TDS sampling, and calibration can be provided by Fulton if required. In order to achieve the maximum benefit from the installation of an Automatic TDS Blowdown System, it is strongly recommended that site personnel be provided with the necessary equipment, and training in order for them to fully understand the function of the system, and the possible consequences of their actions.

Note: Where Automatic TDS Blowdown systems are provided as part of a skid mounted or packaged plantroom system, they will be fully installed piped and wired.

From Fig. 39 TDS Graph 1

Figure. 40 - TDS Graph 2 e.g. Hourly blowdown rate required to maintain a boiler TDS of 2000 with a feedwater TDS of 200 = 12% For a 1000 kg/h boiler 125 kg/h (125 l/h) of blowdown is required.

Page 64 JGASUK-IOMM-2015-2 Fulton Ltd Material & Workmanship Guarantee

5 Year GUARANTEE F U D L T T O N L

On the Fulton Boiler Pressure Vessel

Fulton Ltd will repair or replace EXW 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 guarantee does not cover damage or failures that can be attributed to corrosion, scale or dirt accumulation or to low water conditions. This guarantee is good only in the United Kingdom of Great Britain and Northern Ireland. This guarantee does not include labour or delivery charges of any kind.

General Guarantee

The Fulton general guarantee is given in lieu of cause whatsoever. Defective goods or parts and in exclusion of any warranty expressed or must be returned to us as soon as possible implied, statutory or otherwise, as to the state, after discovery of the defect. Costs of carriage condition, performance, quality or fitness of and of detaching and incorporating parts will the goods. Save thereunder we shall be under be borne by you. In all cases at the termination no obligation or liability of any kind to you in of such 12 months all liability on our part will regard to the goods. In the case of new goods cease. No liability whatsoever is to be incurred manufactured and supplied by us we will make by us in respect of gauge or sight glasses, good any defect developing therein under proper packing glands or electric motors or any goods use within 12 months of delivery, provided that or accessories not of our manufacture. But so after investigation in our sole discretion we are far as we are able, we shall let you have the satisfied that the defect arose from faulty design, benefit of any guarantee or warranty given to us materials or workmanship and from no other in respect thereof.

JGASUK-IOMM-2015-2 Page 65 www.fulton.co.uk

JGASUK-IOMM-2015-2

Fulton Ltd 5 Fernhurst Road Fishponds Bristol BS5 7FG England

Telephone: +44 (0) 117 972 3322 Fax: +44 (0) 117 972 3358 Email: [email protected] 003 FM 28400