FULTON J Series Manuel utilisateur

This manual must be available to the boiler operator at all times. JGASUK-IOMM-2015-2

INSTALLATION, OPERATIONAND MAINTENANCE MANUAL

J Series (UK)

Gas Fired Steam Boiler

(including optional fully modulating burner)

JGASUK-IOMM-2015-2

Fulton Ltd

Page II

JGASUK-IOMM-2015-2

Fulton Ltd

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TABLE OF CONTENTS

SECTION 1 - INTRODUCTION

1.1 General 1

1.2 Technical Data 1

SECTION 2 - INSTALLATION

2.1 General 3

2.2 Siting 3

2.3 Ventilation 4

2.4 Flue Outlet 4

2.5 Water Supply 6

2.6 Blowdown Valve 7

2.7 Main Steam Valve 8

2.8 Steam Safety Valves 8

2.9 Water Level Gauge Set (sight glass) 8

2.10 Gas Supply 8

2.10.1 Gas Valve with Pilot Gas Line 9

2.11 Electrical Requirements 9

2.12 Steam Pressure Gauge 9

2.13 Commissioning the Boiler 11

2.13.1 Boiler Inspection and Initial Firing 11

2.13.2 SettingBurnerControls-low/highre(40J-60J) 14

2.13.3 SettingBurnerControls-fullymodulating(30J-60J) 14

2.14 Multi Bloc Gas Valves 15

2.15 Cleaning Steam Lines and Pressure Vessels 18

SECTION 3 - OPERATION

3.1 General 19

3.2 Boiler Controls 19

3.3 Indicator Lights 21

3.4 Filling the Boiler-all models 22

3.5 Starting the Burner-all models 23

SECTION 4 - MAINTENANCE

4.1 Visual Checks 25

4.2 Water Level and Low Water Safety Controls 25

4.2.1 Pump Test 25

4.2.2 1st Low Water Level Check 26

4.2.3 2nd Low Water Level Check 27

4.3 Main Blowdown 28

4.4 Water Column Blowdown 28

4.5 Water Level Gauge Blowdown 29

4.6 Evaporation Checks 30

4.7 Flame Sensor Test 30

4.8 Draining the Boiler 31

4.9 Long Term Shut Down 32

4.10 Internal Inspection 32

4.11 Schedule of Operator Tests and Checks 33

4.11.1 Daily 34

4.11.2 Weekly-in addition 34

4.11.3 Monthly-in addition 34

4.11.4 Three Monthly-in addition 35

4.11.5 Six Monthly-in addition 35

4.11.6 Annually-in addition 37

4.12.1 Troubleshooting-boiler 38

4.12.2 Troubleshooting-feedwater pump 41

4.12.3 Troubleshooting-burner control unit-LFL1 43

4.13 Maintenance Log 45

APPENDIX A - TI SHEETS

APPENDIX B - WATER LEVEL PROBE INFO

APPENDIX C - MOTORISED HIGH/LOW CONTROL

1.1 General 57

1.2 Operation 57

1.3 Additional Controls 58

1.4 Commissioning 58

1.4.1 Fuel Input Rates 58

1.4.2 Air Damper Motor - Factory Cam Settings 58

1.4.3 Setup Procedure 59

1.5 Spare Parts 59

APPENDIX D - SPIRAX HIGH INTEGRITY LEVEL

CONTROLS

1.1 Daily Tests 61

1.1.1 1st Low Water-daily 61

1.1.2 2nd Low Water-daily 61

1.2 Weekly Test-in addition 62

1.2.1 1st Low Water-weekly in addition 62

1.2.2 2nd Low Water-weekly in addition 62

APPENDIX E - AUTOMATIC TDS BLOWDOWN

SYSTEM

1.1 General 63

Electrical diagrams supplied separately

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WARNINGS

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

SAFETYASSESSMENT FEDERATION Limited.

Nutmeg House,

60 Gainsford Street,

Butlers Wharf,

London, SE1 2NY.

(b) HealthandSafetyExecutivelocalofce.

For your safety!

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

• WARNINGS must be observed to prevent serious

injury or death to personnel.

• CAUTIONS must be observed to prevent damage

or destruction of equipment or loss of operating

effectiveness.

• Notes: must be observed for essential and

effective operating procedures, conditions and as

a statement to be highlighted.

It is the responsibility and duty of all personnel involved

in the operation and maintenance of this equipment

to fully understand the WARNINGS, CAUTIONS and

NOTES by which hazards are to be eliminated or

reduced.

Personnel must become familiar with all aspects of

safety and equipment prior to operation or

maintenance of the equipment.

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rectied.

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 re, explosion, property damage, personal injury or loss of life.

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Fulton Ltd

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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

Do not try to do repairs or any other maintenance work

you do not understand. Obtain a service manual from

Fulton Ltd or call a Fulton service engineer.

It is the responsibility of the installer to ensure all parts

suppliedwiththeboilerarettedinacorrectandsafe

manner.

Understand the electrical circuit before connecting

or disconnecting an electrical component. A wrong

connection can cause injury and or damage.

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

completed before using the boiler.

Do not change the boiler fuel without consulting the

boiler manufacturer.

LIFTING EQUIPMENT

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.

Operating the boiler beyond its design limits can damage

the boiler, it can also be dangerous. Do not operate the

boiler outside its limits. Do not try to upgrade the boiler

performancebyunapprovedmodications.

Non-approvedmodicationscancauseinjuryand

damage. Contact your Fulton dealer before modifying

the boiler.

Only qualied persons should be allowed to

operate and maintain the boiler and its equipment.

Boilers should always be drained through an approved

blowdown vessel.

The installation of gas appliances including the

ue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

qualiedpersonnelshouldworkonorinthelocalityof

a steam boiler and ancillary equipment. Always ensure

theworkingareaandoorareclearofpotentialhazards,

work slowly and methodically.

DoNOTstoreinammablematerialsneartheboiler.

The importance of correct boiler water and feedwater

cannot be over emphasised, see the relevant section in

this manual.

CAUTION

Obey all laws and local regulations which affect you and

your boiler.

LOW FEEDWATER TEMPERATURE

Low feedwater temperature can result in thermal shock

to the boiler pressure vessel. Return the maximum

amount of condensate and if necessary preheat the

feedwater. If in doubt consult Fulton Ltd.

WATER SOFTENER and CHEMICAL TREATMENT

The chemicals required to operate the water softeners

and chemical treatment plants CAN BE SUPPLIED by

Fulton Ltd.

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.

HYDRAULIC TEST - RISK OF BRITTLE FRACTURE

Hydraulic testing requires specialist equipment and

is normally only required by engineering surveyors /

inspectors. In order to ensure the material/ pressure

vessel does not suffer from brittle fracture, hydraulic

testing should not be carried out below 7 °C.

WARNING

DANGER FROM INCOMPLETE COMBUSTION

The importance of correct burner adjustment to achieve

lowemissions,safe,cleanandefcientcombustion

is paramount. Poor combustion, where unburnt gas

forms carbon monoxide is both a health hazard, and

the potential risk to the boiler from overheating, caused

byre-burningoftheunburntgasinthesecondaryue

passes.

Prior to the commencement of any work requiring the

removal of cover plates and the opening of control panel

box, the electrical supply to the boiler must be isolated.

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Fulton Ltd

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Figure. 1 - Non-Modulating Gas Fired Steam Boiler

Monobloc gas valve

Low water level probes

Water column containing

water level probes

Water column

blowdown valve

Water level gauge

(sight glass)

Water level gauge

blowdown valves

Steam pressure limiter

Clean out handhole

(water jacket)

Steam pressure control

Pressure gauge

Air pressure

switch

Air intake

Boiler control

panel

Control box

door lock

Control box

isolator switch

Clean out door

(furnace)

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Fulton Ltd

Page 1

INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

TheFultonJSeriesgasredsteamboilerservicemanualisagenericpublication,providing

informationonstandardboileroperationandmaintenance.TheJSeriesgasredsteamboileris

averticaltwo-passboilerofsimple,efcient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specicationrefertoAppendix A - TI-117-J Series Dimensions & Specication.

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

Fulton Ltd

Page 2

Figure. 2 - Fully Modulating Gas Fired Steam Boiler

Steam pressure

limiter

Clean out handhole

(water jacket)

Pressure transducer

Air intake

containing main air

control

Boiler control panel

Control box

door lock

Control box isolator

switch

Clean out door

(furnace)

AZL burner control

RWF40

PID Controller

BT1050

Boiler blowdown

timer(iftted)

BC3150

Blowdown controller

(iftted)

LC3050

Level limiters

(iftted)

Low water level

probes

Water column

containing water

level probes

Water column

blowdown valve

Water level gauge

(sight glass)

Water level gauge

blowdown valves

Pressure gauge

Air pressure

switch

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Fulton Ltd

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INSTALLATION - 2

2.1 GENERAL

TheinstallationofaJSeriesgasred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sufciently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 & Specication 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.

SECTION 2 - INSTALLATION

Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthto

support the boiler.

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Fulton Ltd

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INSTALLATION - 2

2.4 FLUE OUTLET

2.3 VENTILATION

Adequatefresh,cleanairisnecessaryforsafeandefcient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

ue and cause the burner to lock out on ame failure.

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

Theboilerissuppliedwithastainlesssteeluespigotthatshouldbeinsertedintotheue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uewillbesubjecttolocalplanningregulationsandapprovals.

The following information is only intended to provide assistance for the installation of a simple

ue.Wheremulti-boileruesordifcultiesareexperienced,specialistadviceshouldbeobtained.

Theuediametermustbethesameorlargerthantheueange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tted,careshouldbetakentoensurethatthedistancebetweenthelowestpoint

ofthecowlandthetopoftheueis1.5xthediameteroftheueandthatitisoftheterminal

cone type.

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

Note: Avoid tting 90° elbows whenever possible, if unavoidable compensate by increasing the ue diameter.

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

Figure. 3 - Boiler Flue Connection

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