Fulton J Series User manual

Brand: Fulton

Model: J Series

Type: User manual

This manual must be available to the boiler operator at all times. J-IOMM-2017-2

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

J Series

Gas / Oil / Dual Fuel Fired Steam Boilers

(including optional fully modulating burner)

J-IOMM-2017-2

Fulton Ltd

Page II

TABLE OF CONTENTS

I Warnings & Cautions Explained IV

II Warnings & Cautions In Manual IV

III Regulations VII

SECTION 1 - INTRODUCTION

1.1 General 1

1.2 Technical Data 1

1.3 Product Overview 1

SECTION 2 - INSTALLATION

2.1 General 5

2.2 Pre-Installation 5

2.2.1 Receiving Inspection 5

2.2.2 Siting 6

2.3 Ventilation 6

2.4 Connections 10

2.4.1 Flue Outlet 10

2.4.2 Blowdown Valves 11

2.4.2.1 Main Boiler Blowdown Valve 11

2.4.2.2 Water Bottle 12

2.4.2.3 Water Level Gauge Set (sight glass) 12

2.4.3 Steam Safety Valve 13

2.4.4 Main Steam Valve 13

2.4.5 Steam Pressure Gauge 14

2.5 Fuel Supply 15

2.5.1 Gas Supply 15

2.5.1.2 Gas Valve with Pilot Gas Line 15

2.5.1.3 L.P.Gas-Gas Supply - Propane / Butane 16

2.5.2 Oil Supply 17

2.6 Electrical Requirements 18

2.6.1 Electrical Customer Connections 19

2.7 Water Supply 21

2.7.1 Glossary of Water Supply Terms 22

2.8 PipingSpecications 23

2.9 Insulation 24

2.10 Pipework leak/Pressure Tests 24

SECTION 3 - COMMISSIONING

3.1 Commissioning the Boiler 25

3.1.1 Boiler Inspection And Initial Firing-DUAL FUEL Burner 26

3.1.2 Boiler Inspection And Initial Firing-Gas Burner 27

3.1.3 Boiler Inspection And Initial Firing-OIL Burner 29

3.2 Setting the Burner Controls-GAS Burner 31

3.2.1 Low/High Fire (40J - 60J) 31

3.2.2 fully modulating (30J - 60J) 31

3.3 Gas Monoblocs-Non Modulating Burner 32

3.3.1 Multi Bloc Gas Valves 33

3.4 Cleaning Steam Lines and Pressure Vessels 36

SECTION 4 - OPERATION

4.1 General 37

4.2 Controls 37

4.2.1 Boiler Controls 38

4.2.2 Boiler Control Panel 39

4.2.3 Steam Pressure Controls 42

4.2.3.1 Setting Pressure Controls 43

4.2.3.2 Testing Steam Pressure Controls 44

4.3 Changing To The Alternative Fuel-Dual Fuel Burner 44

4.4 Filling the Boiler-all models 45

4.5 Draining the Boiler 46

4.6 Boiler Start-Up (from cold)-all models 47

4.6.1 Boiler Start-Up Following Short Term Shut-Down 48

4.7 Boiler Shut-Down 48

4.7.1 Short Term Shut-Down (hours) 48

4.7.2 Medium Term Shut-Down (days) 48

4.7.3 Long Term Shut-Down (weeks) 48

SECTION 5 - MAINTENANCE

5.1 Boiler Platform (if Fitted) 49

5.2 Visual Checks 49

5.3 Burner Flame Sensor Test 50

5.4 Water Level and Low Water Safety Control Procedures 51

5.4.1 Feedwater Pump Test 51

5.4.2 Low Water Level Check 52

5.4.3 Evaporation Check 52

5.5 Blowdown Procedures 53

5.5.1 Main Boiler Blowdown (manual) 53

5.5.2 Water Bottle Blowdown 53

5.5.3 Water Level Gauge (Sight Glass) Blowdown 54

5.6 Boiler Internal Inspection 55

5.7 Fitting New Gaskets To Boiler Inspection Holes 55

5.7.1 Important Information 55

5.7.2 Fitting Procedure 56

5.8 Schedule of Operator Tests and Checks 57

5.8.1 Daily 58

5.8.2 Weekly-in addition 58

5.8.3 Monthly-in addition 59

5.8.4 Six Monthly Service 59

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TABLE OF CONTENTS

Electrical diagrams supplied separately

5.8.5 Annual Service 60

5.8.6 After 5 Years 60

5.8.7 After All Repairs & Maintenance in addition 60

5.9 Maintenance Record Keeping 61

SECTION 6 - TROUBLESHOOTING

6.1 Troubleshooting-Gas boiler 63

6.2 Troubleshooting-Oil boiler 67

6.3 Troubleshooting-feedwater pump 72

6.4 Troubleshooting-burner control unit-LFL 1 (Siemens) 74

APPENDIX A - TI SHEETS

 JSeriesDimensions&Specication 78

J Series Probe Lengths 80

Recommended Water Conditions 81

Water Level Probes 82

Auto TDS Blowdown Systems 84

APPENDIX B - WIRING DIAGRAMS

1.1 General 87

APPENDIX C - SPARE PARTS

1.1 Ordering Spares 89

APPENDIX D - MOTORISED HIGH/LOW CONTROL

1.1 General 91

1.2 Operation 91

1.3 Additional Controls 92

1.4 Commissioning 92

1.4.1 Fuel Input Rates 92

1.4.2 Air Damper Motor 92

1.4.3 Setup Procedure 93

1.5 Spare Parts 93

APPENDIX E - SPIRAX HIGH INTEGRITY LEVEL

CONTROLS

1.1 Daily Tests 95

1.1.1 Low Water daily 95

1.2 Weekly Test in addition 96

1.2.1 Low Water weekly in addition 96

APPENDIX F - Set Back Control

(On/Off or High/Low Control Modes)

1.1 Description 97

1.2 Pressure Settings 97

1.3 Automatic (Time Clock) Control 99

1.4 Local Control 99

1.5 Remote Override 99

1.6 Setback Status 100

1.7 Boiler Operating Status Screens 100

1.8 Boiler Operating Hours 102

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Page IV

SAFETY PRECAUTIONS

SAFETY

The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in

damage to the boiler and serious personal injury.

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.

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.

I WARNINGS & CAUTIONS EXPLAINED

II WARNINGS & CAUTIONS IN MANUAL

Escapinggascanleadtoexplosionswhichmayresultinseriousinjury.

WHAT TO DO IF YOU SMELL GAS:

• Donotusematches,candles,ameorothersourcesofignitiontocheckforgasleaks.

• Do not try to light the appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Immediately call your gas supplier from a safe location.

• Followthegassupplier’sinstructions.Ifyoucannotreachyourgassupplier,calltheredepartment.

Flue Gas can lead to life threatening poisoning.

WHAT TO DO IF YOU HAVE A FLUE GAS LEAK:

• Shut down the heating system.

• Ventilate the boiler room.

• Close all doors leading to the living space.

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SAFETY PRECAUTIONS

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.

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.

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.

Boilers should always be drained through an approved

blowdown vessel.

This boiler is equipped with an ignition device, which

automatically lights the burner. Do not try to light the

burner by hand.

Label all wires prior to disconnection when servicing

controls. Wiring errors can cause improper and

dangerous operation.

Never attempt to operate equipment that has failed to

pass all the safety checks.

Follow proper lockout procedures for the electrical, gas

and water connections.

If any “Manual Reset” limit device trips, DO NOT reset

without determining and correcting the cause. (Manual

ResetLimitsmayinclude:amesafeguard,highorlow

gas pressure, high temperature limit, high pressure

limit.)

Never tamper with low water (liquid level) cut-off

sensors or circuitry.

Before commissioning the equipment, verify with

authorized personnel that gas lines have been purged.

Check daily that the equipment area is free and clear

ofanycombustiblematerials,includingammable

vapours & liquids.

Donotstoreorusegasolineorotherammable

vapours and liquids or corrosive materials in the vicinity

of this or any other appliances. Cements for plastic pipe

should be kept away from all sources of ignition.

Proper ventilation should be maintained to reduce the

hazard and to minimize breathing of cement vapours.

No shut-off of any kind shall be placed between

the safety relief valve and the equipment or in

the discharge pipe between such valve and the

atmosphere. Doing so can cause an accidental

explosion from overpressure.

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SAFETY PRECAUTIONS

WARNING

The discharge from the safety relief valve shall be

so arranged that there will be no danger of scalding

personnel or damage to equipment. Provisions should

be made to properly drain safety relief valve discharge

piping.

Fluids under pressure may cause injury to personnel or

damage to equipment when released. Be sure to shut

offallincomingandoutgoinguidshut-offvalvesand

carefully decrease all trapped pressures to zero before

performing any maintenance.

Do not attempt to start the equipment for any testing

priortollingandpurgingthevessel.Adryrewill

seriously damage the equipment and may result in

property damage or personnel injury and is not covered

bywarranty.Incaseofadryringevent,shutoff

the fuel supply and allow the vessel to cool to room

temperaturebeforeuidisreintroducedtothepressure

vessel.Theboilershouldbeinspectedbyaqualied

individual prior to commissioning the unit.

When opening any drains on the equipment or piping

system, steps should be taken to avoid scalding/

burningofpersonnelduetohotuids.Whenever

possible, the system should be cooled prior to opening

any drains.

Hot surfaces (over 49 °C) should be insulated or

shielded for safety. See Installation section.

Should overheating occur or the gas supply fails to shut

off, manually shut off the gas supply external to the

equipment.

Improper installation or maintenance of gauge glass

and connections can cause immediate or delayed

breakage resulting in bodily injury and/or property

damage. Only properly trained personnel should install

and maintain gauge glass connections. Wear safety

glasses during installation. Be sure all parts are free of

chips and debris.

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.

CAUTION

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.

The stack arrangement and draft conditions should be

in accordance with the information in this manual for

proper performance of the equipment.

Some soap used for leak testing is corrosive to certain

types of metals. Clean all piping thoroughly after

completing the leak check.

A temperature exceeding 49 °C* in the boiler room

may cause premature failure of electrical components.

Provisions should be made to maintain an ambient

temperature of 49 °C* or less (the panel box interior

should not exceed 52 °C*.

*Pumps, Programmable Logic Controllers (PLC)

or ModSync panels may require lower ambient

temperatures or additional cooling.

Particulate matter or chemicals (example:

perchlorethylene, chlorine, or halogenated compounds)

in the combustion air supply to the boiler will cause

damage or failure to the burner and is not covered

under warranty. High-risk situations for particulate

matter to be in the air include construction and

maintenance activities.

Forallsystemscontainingboilersorunredsteam

generators, the water chemistry in the boiler must be

kept within the limits outlined in this manual. Failure to

do so may cause premature pressure vessel failure and

poor steam quality and will void the warranty.

Do not run the pump dry. Irreparable damage to the

seal can result. Prime the pump in accordance with the

manufacturer’s instructions. Never operate the pump

with a closed discharge valve.

Shouldyoususpectthattheboilersuepassageways

have become blocked, contact your authorized Fulton

representative.

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Page VII

SAFETY PRECAUTIONS

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ofce.

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.

III REGULATIONS

Observe the following when working on this system:

• Workongasequipmentmustonlybecarriedoutbyaqualiedgasengineer.

• Workonelectricalequipmentmustonlybecarriedoutbyaqualiedelectrician.

• All legal instructions regarding the prevention of accidents,

• All legal instructions regarding environmental protection,

• The Code of Practice of relevant trade associations,

• AllcurrentsafetyregulationsasdenedbyDIN,EN,DVGW,TRGI,TRF,VDEandalllocallyapplicable

standards,

• Gas Safety (Installation & Use) Regulations

- The appropriate Building Regulation either the Building regulations, the Building Regulation (Scotland) or

Building Regulations (Northern Ireland),

- The Water Fittings Regulation or Water Bylaws in Scotland,

- The current I.E.T. Wiring Regulations.

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Page VIII

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Page 1

INTRODUCTION - 1

SECTION 1 - INTRODUCTION

1.1 GENERAL

1.2 TECHNICAL DATA

ForafullspecicationrefertoAppendixA-TI-117-JSeriesDimensions&Specication.

1.3 PRODUCT OVERVIEW

TheJSeriesfuelredsteamboilerisatubelessverticaltwo-passboilerofsimple,efcientdesign

and construction.

CONTINUED ON NEXT PAGE

Prior to shipment, the following inspections and tests are made to ensure the highest standards of

manufacturing for our customers:

• Material inspections

• Manufacturing process inspections

• Hydrostatic test inspection

• Electrical components inspection

• Operating test

• Crating inspection

This manual is provided as a guide to the correct operation and maintenance of your Fulton

equipment, and should be read in its entirety and be made permanently available to the staff

responsible for the operation of the boiler. It should not, however, be considered as a complete

code of practice, nor should it replace existing codes or standards which may be applicable.

Fulton reserves the right to change any part of this installation, operation and maintenance

manual.

Installation, start-up, and maintenance of this equipment can be hazardous and requires trained,

qualiedinstallersandservicepersonnel.Trainedpersonnelareresponsiblefortheinstallation,

operation, and maintenance of this product, and for the safety assurance of installation, operation,

and maintenance processes. Do not install, operate, service or repair any component of this

equipmentunlessyouarequaliedandfullyunderstandallrequirementsandprocedures.

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INTRODUCTION - 1

Figure. 1 - Typical General Arrangement

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INTRODUCTION - 1

Figure. 2 - General Arrangement Top

1. Boiler control panel

2. Control panel door lock

3. System controls (blowdown/TDS)

4. Control box isolator switch

5. Operating pressure control switch

6. High limit pressure control switch

7. Clean out door (furnace)

8. Clean out handhole (water jacket)

9. Water level gauges (sight glass)

10. Water level gauges blowdown valves

11. Water bottle containing water level probes

(pump on/off)

12. Water bottle blowdown valve

13. Gas train (gas burners only)

14. Monobloc gas valve

15. Burner scroll (air intake)

16. Air pressure switch

17. Boiler pressure gauge

18. Water level limiters (high/low water)

19. Burneramesensor

20. Ignition electrodes

21. 6 mm peep hole

22. Mainameobservation

23. Boiler safety valve

24. Feedwater inlet

25. Primary/secondary air adjustment

26. TDS system

27. Main steam stop valve

28. Oil line to burner (oil burners only)

Key

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Page 5

INSTALLATION - 2

SECTION 2 - INSTALLATION

Prior to delivery of the boiler, consideration should be given to the following:

(Planning regulations may call for more consents than those listed below, always check with your

Local Planning Authority).

A. Local Planning consents where appropriate.

B. Consideration given to access for delivery and positioning of the boiler.

C. Preparation of a suitable non combustible base, which must be able to support the total weight

of the system under operating conditions.

The locations of services to the site required for the system, under operating conditions.

D. Electricity supply, check the loading required/available.

E. Drainage system, check the suitability of the drainage system.

F. Local regulations for discharge into existing drains.

G. Suitable access for delivery and off-loading.

H. Safe access to the plant when installation is complete.

2.1 GENERAL

TheinstallationofaJseriesfuel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/manufactured gas or 35 sec fuel oil.

Where the boiler is to operate on L.P. Gas, special reference should be made to Section 2.11.1 -

Gas Supply, and Section 2.11.1.3 L.P. Gas.

2.2 PRE-INSTALLATION

The customer should examine the equipment for any damage. It is the responsibility of the installer

toensureallpartssuppliedwiththeequipmentarettedinacorrectandsafemanner.

2.2.1 RECEIVING INSPECTION

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INSTALLATION - 2

2.3 VENTILATION

2.2.2 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.

Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthto

support the boiler.

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.

It is essential that only fresh air be allowed to enter the combustion air system. Foreign

substances in the combustion system can create hazardous conditions. Particulate matter like

lint, combustible volatiles, dust, smog or chemicals (example, perchlorethlylene, halogenated

compounds) in the combustion air supply to the equipment will cause damage or failure of the

burner and is not covered under warranty.

Eliminate potential for high risk situations for particulate matter to be in the air supply (e.g.,

as the result of construction or maintenance activities). If foreign substances can enter the air

stream, the combustion air inlet must be piped to an outside location. Failure to do so will void the

warranty.

Ventilation requirements for LPG. Low level vents should be located as low as reasonably

practicalwithin250mmoftheoorlevel.Highlevelshouldbelocatedashighasreasonably

practical.

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.

WARNING

Failure to provide required and safe access to the equipment could impede commissioning and maintenance.

Service technicians are instructed not to commence commissioning if hazardous conditions exist.

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Figure. 3 - Typical Installation (GAS)

Boiler blowdown valve

Drain

Overflow to

drain

Blowdown

Separator

Vent

Make-up feedwater supply

Stainless steel

feedwater and

condensate

return tank

Note: A break tank may be required depending

upon Local Water Authority bylaws

Overflow

Flexible

connector

Condensate return

Feedwater

pump

Feedwater

non-return

valve

(to be installed below

boiler water level)

Flanged connection

20J - 60J only

Clean-out door

Draught stabiliser

(when fitted)

Standard boiler trim

supplied with boiler

Flue

Cowl

D = Diameter of flue

H = 1.5 X D

Feedwater isolation ball valve

Pipe safety valve

to a safe area,

using unions and

drain as required.

Steam supply

Flue spigot

Water column

blowdown line

Strainer Isolating gate/ball valve Plugged drains

Boiler Water Level

Vent to

Atmosphere

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NOTE: A BREAK TANK MAY

BE REQUIRED CHECK THE

LOCAL WATER AUTHORITY

BYE-LAWS

CONNECTIONS TO OIL STORAGE TANK

OVERFLOW

TO DRAIN

MAKE-UP SUPPLY

FULTON

BLOWDOWN

VESSEL

FIRE VALVE LINE

DRAIN

OIL FILTER

(METAL CARTRIDGE)

OIL FEED LINE

STAINLESS

STEEL

TANK

SET

CHECK

VALVE

FIT AN ISOLATING VALVE IN

OIL RETURN LINE ONLY

IF OIL TANK OR PIPE WORK

IS ABOVE BURNER LEVEL

OIL RETURN LINE

ISOLATING

VALVE

SIGHT GLASS

FEED WATER

PUMP

FLEXIBLE LINK

CONDENSATE RETURN

FEED WATER

CHECK VALVE

(TO BE INSTALLED

BELOW BOILER

WATER LEVEL)

VENT

SLUDGE

COCK

CLEANOUT

DOOR

FILL

DRAUGHT

STABILISER

(WHERE

FITTED)

BOILER BLOWDOWN

VALVE

STANDARD BOILER

TRIM SUPPLIED

WHEN ORDERING

THE BOILER

PIPE SAFETY VALVE

TO SAFE AREA, FITTING

UNIONS AND DRAIN

BALL

VALVE

FLUE

SPIGOT

STEAM SUPPLY

H = 1.5 X D

WATER

COLUMN

BLOWDOWN

LINE

Flue

Cowl

ISOLATING VALVE

STRAINER

OVERFLOW

BOILER WATER LEVEL

Figure. 4 - Typical Installation (OIL)

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STANDARD BOILER TRIM SUPPLIED

WHEN ORDERING THE BOILER

STEAM

SUPPLY

WATER

Bottle

BLOWDOWN

LINE

PIPE SAFETY VALVE

TO SAFE AREA, FITTING

UNIONS AND DRAIN

STOP

VALVE

FEEDWATER

CHECK VALVE

(TO BE INSTALLED

BELOW BOILER

WATER LEVEL)

FLUE

FLANGE CLEAN-OUT

DOOR

DRAUGHT

STABILISER

(WHERE

FITTED)

MAIN BLOWDOWN

VALVE

FEED PUMP

STRAINER

CONDENSATE

RETURN

OVERFLOW

OIL

STORAGE

TANK

SLUDGE

COCK

FILL

VENT

FLEXIBLE

LINK

ISOLATING

VALVE

CHECK

VALVES DRAIN

STAINLESS

STEEL

TANK SET

ISOLATING

VALVE

CHECK

VALVE

SIGHT

GAUGE FIRE VALVE

LINE

OIL RETURN LINE

FIT AN ISOLATING VALVE IN OIL RETURN

LINE ONLY IF OIL TANK OR PIPEWORK

IS ABOVE BURNER LEVEL

OIL FILTER

(METAL CARTRIDGE)

OIL FEED

LINE

MAKE-UP SUPPLY

CONNECTIONS TO OIL STORAGE TANK

FULTON

BLOWDOWN

SEPARATOR

OVERFLOW

TO DRAIN

TO FUSIBLE LINK

NOTE:- A BREAK TANK MAY BE

REQUIRED CHECK THE LOCAL

WATER AUTHORITY BYE-LAWS

BOILER WATER LEVEL

Figure. 5 - Typical Installation (DUAL FUEL)

Note: Both gas and oil fuel supply lines must be tted with isolation valves with proof of closure microswitches which must be electronically interlocked with the burner gas and oil control circuits.

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INSTALLATION - 2

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. 6 - Boiler Flue Connection

CAUTION

Concentration levels of only a few ppm of chlorine containing compounds in combustion air can

produceseriouscorrosionoftheueoverlongperiodsoftime.Highchlorinecontainingcompounds

such as carbon tetrachloride or perchloroethylene would be prime suspects.

WARNING

To maintain a reasonable temperature in the equipment area and ensure safety to personnel, the

section of the chimney duct within the building should be insulated.

2.4.1 FLUE OUTLET

2.4 CONNECTIONS

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INSTALLATION - 2

2.4.2 BLOWDOWN VALVES

2.4.2.1 MAIN BOILER BLOWDOWN VALVE

There are four blowdown valves on the boiler, the boiler blowdown valve at the rear of the boiler,

the water bottle 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 or Health and Safety Executive

Guidance Note PM60 which covers blowdown tanks and associated pipework installation.

WARNING

Never discharge blowdown from the boiler directly to a drain. Where a high level of blowdown or automatic

blowdownsystemsareinstalled,seriousconsiderationshouldbegiventottingaBlowdownAfterCooling

System.

8J - 15J

Main blowdown connection is via a branch pipe.

20J - 60J

Mainblowdownconnectionisintegral,viaaboilermountedange.

Where possible the main blowdown pipework on 20J - 60J boilers should drop down to a

unionconnectiontoallowremovaloftheinspectionangewithoutthenecessitytoremovethe

blowdown pipework.

Figure. 7 - Boiler Blowdown- models 8J - 15J

(skid mounted boiler shown) Figure. 8 - Flanged Boiler Blowdown- models

20J - 60J (skid mounted boiler shown)

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INSTALLATION - 2

Figure. 9 - Water Level Gauges & Water Bottle Installation

2.4.2.2 WATER BOTTLE

Boilers are supplied with a water bottle containing the pump On/Off probes. The water bottle

blowdown cock should be connected to the auxiliary blowdown line.

2.4.2.3 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

bottle blowdown valve by 3/8 in. soft copper tubing.

For water level gauge operating positions please see Figure. 37 on page 54.

WARNING

Improper installation or maintenance of the water level gauge assembly can cause immediate or

delayedbreakageresultinginbodilyinjuryand/orpropertydamage.

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Fulton J Series User manual

Fulton J Series User manual

Fulton J Series User manual

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