Fulton J Series User manual

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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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Page III
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suppliers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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Page VI
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.
(c) Your Competent Person.
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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Page 2
INTRODUCTION - 1
Figure. 1 - Typical General Arrangement
1
2
3
4
5
7
8
6
10
9
11
12
13
14
15
16
17
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INTRODUCTION - 1
17
18
19
20
21
22
23
24
25
26
27
28
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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Page 6
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
D
H
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
H
D
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.
!
/