INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Transcription

1 INSTALLATION, OPERATION AND MAINTENANCE MANUAL J Series Gas / Oil / Dual Fuel Fired Steam Boilers (including optional fully modulating burner) This manual must be available to the boiler operator at all times.

2 TABLE OF CONTENTS Fulton Ltd I Warnings & Cautions Explained IV II Warnings & Cautions In Manual IV III Regulations VII SECTION 1 - INTRODUCTION 1.1 General Technical Data Product Overview 1 SECTION 2 - INSTALLATION 2.1 General Pre-Installation Receiving Inspection Siting Ventilation Connections Flue Outlet Blowdown Valves Main Boiler Blowdown Valve Water Bottle Water Level Gauge Set (sight glass) Steam Safety Valve Main Steam Valve Steam Pressure Gauge Fuel Supply Gas Supply Gas Valve with Pilot Gas Line L.P.Gas-Gas Supply - Propane / Butane Oil Supply Electrical Requirements Electrical Customer Connections Water Supply Glossary of Water Supply Terms Piping Specifications Insulation Pipework leak/pressure Tests 24 SECTION 3 - COMMISSIONING 3.1 Commissioning the Boiler Boiler Inspection And Initial Firing-DUAL FUEL Burner Boiler Inspection And Initial Firing-Gas Burner Boiler Inspection And Initial Firing-OIL Burner Setting the Burner Controls-GAS Burner Low/High Fire (40J - 60J) fully modulating (30J - 60J) Gas Monoblocs-Non Modulating Burner Multi Bloc Gas Valves Cleaning Steam Lines and Pressure Vessels 36 SECTION 4 - OPERATION 4.1 General Controls Boiler Controls Boiler Control Panel Steam Pressure Controls Setting Pressure Controls Testing Steam Pressure Controls Changing To The Alternative Fuel-Dual Fuel Burner Filling the Boiler-all models Draining the Boiler Boiler Start-Up (from cold)-all models Boiler Start-Up Following Short Term Shut-Down Boiler Shut-Down Short Term Shut-Down (hours) Medium Term Shut-Down (days) Long Term Shut-Down (weeks) 48 SECTION 5 - MAINTENANCE 5.1 Boiler Platform (if Fitted) Visual Checks Burner Flame Sensor Test Water Level and Low Water Safety Control Procedures Feedwater Pump Test Low Water Level Check Evaporation Check Blowdown Procedures Main Boiler Blowdown (manual) Water Bottle Blowdown Water Level Gauge (Sight Glass) Blowdown Boiler Internal Inspection Fitting New Gaskets To Boiler Inspection Holes Important Information Fitting Procedure Schedule of Operator Tests and Checks Daily Weekly-in addition Monthly-in addition Six Monthly Service 59 Page II

3 TABLE OF CONTENTS Annual Service After 5 Years After All Repairs & Maintenance in addition Maintenance Record Keeping 61 SECTION 6 - TROUBLESHOOTING 6.1 Troubleshooting-Gas boiler Troubleshooting-Oil boiler Local Control Remote Override Setback Status Boiler Operating Status Screens Boiler Operating Hours 102 Electrical diagrams supplied separately 6.3 Troubleshooting-feedwater pump Troubleshooting-burner control unit-lfl 1 (Siemens) 74 APPENDIX A - TI SHEETS J Series Dimensions & Specification 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 Operation Additional Controls Commissioning Fuel Input Rates Air Damper Motor Setup Procedure Spare Parts 93 APPENDIX E - SPIRAX HIGH INTEGRITY LEVEL CONTROLS 1.1 Daily Tests Low Water daily Weekly Test in addition Low Water weekly in addition 96 APPENDIX F - Set Back Control (On/Off or High/Low Control Modes) 1.1 Description Pressure Settings Automatic (Time Clock) Control 99 Page III

4 SAFETY PRECAUTIONS Fulton Ltd I Warnings & Cautions Explained 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. II Warnings & Cautions In Manual! 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. Escaping gas can lead to explosions which may result in serious injury. WHAT TO DO IF YOU SMELL GAS: Do not use matches, candles, flame 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 fire 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. 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. Page IV

5 SAFETY PRECAUTIONS! WARNING! 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 fitted 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 modifications. Non-approved modifications can cause injury and damage. Contact your Fulton dealer before modifying the boiler. Only qualified persons should be allowed to operate and maintain the boiler and its equipment. The installation of gas appliances including the 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. DANGER FROM INCOMPLETE COMBUSTION The importance of correct burner adjustment to achieve low emissions, safe, clean and efficient 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 flue 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: flame 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 flammable vapours & liquids. Do not store or use gasoline or other flammable 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. Page V

6 SAFETY PRECAUTIONS Fulton Ltd! WARNING! CAUTION 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 fluid 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 filling and purging the vessel. A dry fire 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 firing event, shut off the fuel supply and allow the vessel to cool to room temperature before fluid is reintroduced to the pressure vessel. The boiler should be inspected by a qualified 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 fluids. 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. 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 unfired 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 flue passage ways have become blocked, contact your authorized Fulton representative. Page VI

7 SAFETY PRECAUTIONS III Regulations Observe the following when working on this system: Work on gas equipment must only be carried out by a qualified gas engineer. Work on electrical equipment must only be carried out by a qualified 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 defined 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.! 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. 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) (b) (c) SAFed SAFETY ASSESSMENT FEDERATION Limited. Nutmeg House, 60 Gainsford Street, Butlers Wharf, London, SE1 2NY. Health and Safety Executive local office. Your Competent Person. Page VII

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9 INTRODUCTION - 1 SECTION 1 - INTRODUCTION 1.1 General 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, qualified 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 qualified and fully understand all requirements and procedures. 1.2 Technical Data For a full specification refer to Appendix A - TI-117-J Series Dimensions & Specification. 1.3 Product Overview The J Series fuel fired steam boiler is a tubeless vertical two-pass boiler of simple, efficient design and construction. CONTINUED ON NEXT PAGE Page 1

10 INTRODUCTION - 1 Fulton Ltd Figure. 1 - Typical General Arrangement Page 2

11 INTRODUCTION Figure. 2 - General Arrangement Top Key 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 flame sensor 20. Ignition electrodes mm peep hole 22. Main flame 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) Page 3

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13 INSTALLATION - 2 SECTION 2 - INSTALLATION 2.1 General The installation of a J series fuel 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/manufactured gas or 35 sec fuel oil. Where the boiler is to operate on L.P. Gas, special reference should be made to Section Gas Supply, and Section L.P. Gas. 2.2 Pre-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 Receiving Inspection 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 fitted in a correct and safe manner. Page 5

14 INSTALLATION - 2 Fulton Ltd Siting! 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. (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. 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 and IGE/UP/10 Part 1 Communication 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 floor 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 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. Page 6

15 Cowl Steam supply Pipe safety valve to a safe area, using unions and drain as required. Feedwater isolation ball valve Standard boiler trim supplied with boiler D H D = Diameter of flue H = 1.5 X D Flue Flue spigot Draught stabiliser (when fitted) Clean-out door Vent to Atmosphere Note: A break tank may be required depending upon Local Water Authority bylaws Water column blowdown line Boiler Water Level Flanged connection 20J - 60J only Feedwater non-return valve (to be installed below boiler water level) Condensate return Feedwater pump Overflow Flexible connector Stainless steel feedwater and condensate return tank Make-up feedwater supply Vent Blowdown Separator Overflow to drain B oiler blowdown valve Drain Strainer Isolating gate/ball valve Plugged drains Figure. 3 - Typical Installation (GAS) Page 7

16 D Cowl H H = 1.5 X D STANDARD BOILER TRIM SUPPLIED WHEN ORDERING THE BOILER FIT AN ISOLATING VALVE IN OIL RETURN LINE ONLY IF OIL TANK OR PIPE WORK IS ABOVE BURNER LEVEL FIRE VALVE LINE Flue PIPE SAFETY VALVE TO SAFE AREA, FITTING UNIONS AND DRAIN FILL VENT OIL RETURN LINE STEAM SUPPLY BALL VALVE DRAUGHT STABILISER (WHERE FITTED) SLUDGE COCK SIGHT GLASS ISOLATING VALVE CHECK VALVE OIL FILTER (METAL CARTRIDGE) OIL FEED LINE BOILER WATER LEVEL WATER COLUMN BLOWDOWN LINE FLUE SPIGOT CLEANOUT DOOR FEED WATER CHECK VALVE (TO BE INSTALLED BELOW BOILER WATER LEVEL) OVERFLOW FLEXIBLE LINK CONDENSATE RETURN FEED WATER PUMP STAINLESS STEEL TANK SET CONNECTIONS TO OIL STORAGE TANK MAKE-UP SUPPLY NOTE: A BREAK TANK MAY BE REQUIRED CHECK THE LOCAL WATER AUTHORITY BYE-LAWS OVERFLOW TO DRAIN BOILER BLOWDOWN VALVE FULTON BLOWDOWN VESSEL DRAIN STRAINER ISOLATING VALVE Figure. 4 - Typical Installation (OIL) Page 8

17 STANDARD BOILER TRIM SUPPLIED WHEN ORDERING THE BOILER FIT AN ISOLATING VALVE IN OIL RETURN LINE ONLY IF OIL TANK OR PIPEWORK IS ABOVE BURNER LEVEL TO FUSIBLE LINK SIGHT GAUGE FIRE VALVE LINE FILL VENT OIL RETURN LINE STEAM SUPPLY PIPE SAFETY VALVE TO SAFE AREA, FITTING UNIONS AND DRAIN STOP VALVE OIL STORAGE TANK ISOLATING VALVE OIL FILTER (METAL CARTRIDGE) DRAUGHT STABILISER (WHERE FITTED) SLUDGE COCK CHECK VALVE OIL FEED LINE WATER Bottle BLOWDOWN LINE FLUE FLANGE BOILER WATER LEVEL MAIN BLOWDOWN VALVE CLEAN-OUT DOOR CONDENSATE RETURN FEEDWATER CHECK VALVE (TO BE INSTALLED BELOW BOILER WATER LEVEL) STRAINER FEED PUMP OVERFLOW FLEXIBLE LINK ISOLATING VALVE CONNECTIONS TO OIL STORAGE TANK MAKE-UP SUPPLY STAINLESS STEEL TANK SET CHECK VALVES DRAIN FULTON BLOWDOWN SEPARATOR NOTE:- A BREAK TANK MAY BE REQUIRED CHECK THE LOCAL WATER AUTHORITY BYE-LAWS OVERFLOW TO DRAIN Note: Both gas and oil fuel supply lines must be fitted with isolation valves with proof of closure microswitches which must be electronically interlocked with the burner gas and oil control circuits. Figure. 5 - Typical Installation (DUAL FUEL) Page 9

18 INSTALLATION - 2 Fulton Ltd 2.4 Connections 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. 6 - Boiler Flue Connection! 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.! CAUTION Concentration levels of only a few ppm of chlorine containing compounds in combustion air can produce serious corrosion of the flue over long periods of time. High chlorine containing compounds such as carbon tetrachloride or perchloroethylene would be prime suspects. Page 10

19 INSTALLATION Blowdown VALVES 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 fitting a Blowdown After Cooling System Main Boiler Blowdown VALVE 8J - 15J Main blowdown connection is via a branch pipe. 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. 7 - Boiler Blowdown- models 8J - 15J (skid mounted boiler shown) Figure. 8 - Flanged Boiler Blowdown- models 20J - 60J (skid mounted boiler shown) Page 11

20 INSTALLATION - 2 Fulton Ltd 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 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. Figure. 9 - Water Level Gauges & Water Bottle Installation! 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. Page 12

21 INSTALLATION Steam Safety VALVE! 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. 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 BSEN :2012 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. d) Ensure pipes and connections are clean and free of any foreign material. e) Do not install using a pipe wrench. Use the appropriately sized wrench on the bonnet nut. f) Install the valve vertically with no unnecessary intervening piping between the boiler and the valve. g) Do not cap or plug the weep hole on the side of the safety valve. h) A discharge pipe shall be of a pipe size equal to, or greater than, the outlet of the safety valve. i) Minimize discharge piping fittings and overall piping run to avoid over pressurization of the piping, limiting safety valve discharge volume. j) Do not support discharge piping with the safety valve. Discharge piping must be supported adequately by appropriate means. k) Terminate the discharge pipe directly to atmosphere. Discharge pipe must not contain a shut off valve of any sort. l) A drain pipe is to be fitted to the lowest point of the discharge pipework. Pipe size to be no greater than 10 mm Main Steam VALVE The main steam stop valve should be inserted in the steam line approximately 305 mm from the top of the boiler. Distribution pipework should be run from the main steam valve on top of the boiler to the steam delivery point(s). Care should be taken to ensure that adequate condensate drainage and expansion facilities are provided within the pipework run(s). To prevent excessive loads being imposed on the main steam isolating valve, the pipework should be secured near the boiler, ensuring adequate flexibility exists in the pipework between the steam valve and the securing point, to minimise any loads imposed on the valve. Page 13

22 INSTALLATION - 2 Fulton Ltd Steam Pressure Gauge The steam pressure gauge assembly should be assembled in accordance with Figure. 10 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 /Test Point Steam Cock Test Point 1/4 in. Copper tube connection to pressure control Syphon Figure Steam Pressure Gauge Page 14

23 INSTALLATION Fuel Supply! WARNING Do not change the boiler fuel without consulting the boiler manufacturer 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 working 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. Main gas line isolating valve Main gas valve assembly Pilot line ball valve Pilot line governor Pilot line gas valves Figure Natural Gas Supply 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. Page 15

24 INSTALLATION - 2 Fulton Ltd L.P.Gas Gas Supply - Propane / Butane LPG Boilers should be installed to the requirements of IGE/UP/10 March 2001 and only by experienced engineers familiar with LPG firing. 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. Further information Firing LPG fuels in a Fulton Vertical Tubeless boiler is relatively straightforward, however the nature of the fuel makes it difficult to ensure that the correct gas flow rate is achieved when commissioning and servicing the burner. LPG is stored as a liquid at high pressure, which is vaporised as the pressure reduces through the pressure regulator at the discharge from the tank. The storage tank pressure regulators typically reduce the pressure down to mbar, which is too high for the inlet to the gas control valve on the Fulton burner. An intermediate or Service Governor is therefore required to reduce the pressure further to below 80 mbar. The siting of the LPG storage tank can be crucial particularly in environments where high ambient temperatures may be experienced. The effect of world wide temperature changes such as caused by solar gain, can result in significant LPG supply pressure change over a 24 hour period. The consequences of temperature and pressure changes, is to vary the density of the gas such that accurate, consistent, and meaningful measurement of the gas flow rate is difficult. Calibrating, gas flow meters to any degree of practical accuracy is extremely difficult. At best an LPG gas meter gives an approximation of the gas flow rate, however the installation of a meter is essential. Where no metering is available the only available criteria to assess the flow rate is the burner inlet gas supply pressure at the test nipple on the last elbow prior to the gas entering the burner. This pressure would normally be established during works testing after manufacture, however LPG firing is not possible at the Fulton Boiler Works Bristol factory, for both practical and safety reasons. The figures given in the Operation and Maintenance Instructions, are calculated figures based on published data for the Specific Gravity of standard Propane and Butane at 15.6 C. In practice temperature, pressure and gas constituents variations, are such that the calculated figure should only be used as a guide. LPG fuels generally produce higher flame temperatures (Butane being the highest) which makes it vital that the burners are not over fired, or are operated with any significant levels of Carbon Monoxide (CO) in the exhaust gas, which could lead to overheating of the boiler pressure vessel. Page 16

25 INSTALLATION - 2 The golden rule with LPG fuels is therefore when in doubt, under fire, ensuring that there is adequate adjustment remaining on the air inlet damper for additional air, and that the exhaust gas analysis readings are 0-10 ppm of CO maximum, with CO2 in the range % maximum.! IMPORTANT Do not attempt to set up an LPG fired burner without a flue gas analyser Oil Supply The positioning of the oil storage tank will be dependent on site conditions and local regulations. The burner fuel pump is of the bypass type requiring the installation of feed and return lines between the oil storage tank and the boiler. These lines should be in tubing of a minimum bore of 10 mm - 15 mm. A fire valve, stop valve and check valves should be inserted in the oil feed line. To avoid blockages in the fuel pump and burner nozzle, a metal cartridge oil filter should be fitted. Fibrous cartridge filters are not recommended. The final connections between the fuel pump and the feed and return lines should be made with the flexible fuel lines supplied. If the oil storage tank is positioned higher than the boiler, a nonreturn valve should be fitted to the return line. To overcome suction problems at the fuel pump, all vertical lifts in the feed pipe should be made as close to the boiler as possible. The burner fuel pump pressure is pre-set at the factory and should not require adjustment. Oil pump Oil feed solenoid valves Oil feed lines connections Oil Outlet Oil inlet Main air adjustment plate Figure Oil Supply Page 17

26 INSTALLATION - 2 Fulton Ltd 2.6 Electrical Requirements! CAUTION Any electrical work should be undertaken by a qualified electrician to current local regulations.! WARNING Assure all electrical connections are powered down prior to attempting replacement or service of electrical components or connections of the equipment. An individual wiring diagram for the boiler is located on the inside cover of the control box. Make sure the information on the electrical drawing corresponds to your voltage and frequency. Check the supply voltage and make sure that there is no over-or under-voltage exceeding 10% of the nominal value. 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. A wall-mounted, fused disconnect sized for the unit must be provided and fitted by the client/ contractor, if disconnect is not supplied on the panel. Connect power to the terminal strip as supplied on the inside of the panel box. Note: Single skid systems are generally shipped completely pre-wired. Note: The power ratings and requirements are given in Appendix A - TI-117-J Series Dimensions & Specification. Note: It is advisable for dual fuel burners, that the offline fuel is manually isolated with a proof of closure microswitch that is interlocked with the online control circuit. e.g. gas supply proof of closure interlocked with the oil burner control circuit. Oil supply proof of closure interlocked with the gas burner control circuit. Page 18

27 INSTALLATION Electrical Customer Connections Remote Stop. The Remote Stop option allows the customer to fit a remote stop pushbutton / contact. An open contact will stop the boiler. It should be wired between terminals 13 & 15 as shown. If a Remote Alarm panel is fitted, wire the remote stop between terminals 13 & 14. Note: A factory fitted link must be removed to use this option (Contact Rating 230V 4A Min.). Common Alarm Contact. A Common Alarm Volt Free Contact is provided for giving a Remote Common Alarm signal or connecting to a site BMS system. (Contact Rating 230V 5A). Pump Interrupt. A Pump Interrupt option allows the customer to fit a remote switch to interrupt the boiler feed water pump. Switch should be an open contact to interrupt the pump operation. A factory fitted link must be removed to use this option. Bottom Blowdown Valve. Connect the Bottom Blowdown valve as shown. A controller in the control panel will then allow automatic bottom blowdown to occur on a time basis. The contact gives feed back to the controller that blowdown valve has opened and closed as required. (Valve supply Max. rating 250V 3A resistive, 250V 1A inductive. Valve switch contact rating 230V 10A Max.). TDS Solenoid Valve. Connect the TDS Solenoid valve as shown. A controller in the control panel will then allow automatic TDS blowdown to occur as required by monitoring the TDS in the boiler. (Valve supply Max. rating 250V 3A resistive, 250V 1A inductive). Blowdown Alarm. The blow down alarm is triggered if a high TDS value is measured or if bottom blowdown is triggered but the valve contact does not open within a specified time indicating a valve failure. (Max. rating 250V 3A resistive, 250V 1A inductive). Fan Dilution Pressure Switch. Depending on the installation, a Flue dilution system and/or a plant room ventilation system may be required. These are safety features to prevent a high contamination of flue gasses in the system. Pressure switches are fitted within the systems to ensure that the required fans are running, hence diluting the flue gasses. If the fans fail, a pressure switch will operate to stop the boiler and prevent further contamination occurring. A factory fitted link must be removed to use this option (230V). Remote Alarm Panel. A remote alarm panel to suit 1,2 or 3 boilers can be fitted in a manned gatehouse. The panel will give an indication of a boiler alarm being triggered and also has the ability to remotely stop the individual boilers. Water softener. A water softener can be powered from the boiler control panel. (230V, 2A Max.). Feed Tank Level Control. A Feed tank level control panel can be powered from the boiler control panel. It controls the level of feed water in the feed water tank if fitted. (230V, 2A Max.). Feed Line Chemical Dosing. A Feed line chemical dosing unit can be powered from the boiler control panel. (230V, 2A Max.). Page 19

28 INSTALLATION - 2 Fulton Ltd Figure Electrical Customer Terminal Connections Page 20

29 INSTALLATION WATER Supply! 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. The Fulton Warranty does not cover damage or failure that can be attributed to excessive corrosion, scale or fouling. 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 20 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 isolation stop valve Feedwater check valve Water level Recommended valve location Feedwater inlet Figure Feedwater check Valve Location Page 21

30 INSTALLATION - 2 Fulton Ltd Feedwater stop valve Feedwater dip pipe Feedwater line Check valve Figure Boiler Feedwater Arrangement Glossary of WATER Supply Terms Dissolved Oxygen: Oxygen that is dissolved in the feedwater will cause the steel in the boiler and the feedwater system to be attacked by the water in a manner described as pitting. The pits that are produced can vary from tiny depressions to holes large enough to penetrate the boiler metal and are usually covered with tubercles of iron oxide. Once pitting starts, it may be extremely hard to arrest. Pitting can proceed at a surprisingly rapid rate and can occur not only in the boiler proper, but also in pre-boiler equipment such as economizers, feedwater tanks, and feedwater lines. Suspended Solids: Suspended solids are the undissolved matter in water, including dirt, silt, vegetation, iron oxides, and any other insoluble matter. Normally suspended solids are expressed in terms of turbidity. Suspended solids may also deposit in low velocity areas and create fouling. In line filters, or various types of pretreatment can be used to lower the suspended solids level. Periodic blowdowns will eliminate suspended solids. Alkalinity: Alkalinity is the capacity of a water to neutralize acids. Common water alkalinities consist of bicarbonate, carbonates, hydroxide, phosphate, and silicate. These alkalinities, especially bicarbonates and carbonates, break down to form carbon dioxide in steam, which is a major factor in the corrosion on condensate lines. High alkalinity also causes foaming and carry over in boilers. Both foaming and carry over cause erratic boiler operation. The reason for the high alkalinity should be determined. It may result from lack of sufficient blow off. The source of alkalinity may be due to an overdose of alkaline internal water treatment chemical. Page 22 ph: ph is a measure of the degree of acid or base of solution. A ph range of will have little influence on the corrosion rate of carbon steel. A low ph can result in corrosion of metals, while a high ph can result in scale formation or caustic embrittlement. In order to control boilers and equipment used for the external treatment of make-up water, it is essential that reliable ph measurements be made. RO/DI water will have a ph of and will require neutralization if used in a carbon steel vessel. It is critical that the boiler ph be alkaline ( ) whenever water is in the boiler. Chlorides: If chloride levels are high enough to cause severe corrosion, they can be controlled by limiting the cycles of concentration and increasing boiler blowdowns. Corrosion from chlorides can also be controlled by increasing the amount of corrosion inhibitor, or changing to a more effective inhibitor. Oil: Oil is not a natural constituent of boiler water; still it can frequently enter a system through leaks in a condenser or other heat exchanger. Oil can also enter a system through the lubrication of steam driven reciprocating equipment. Whatever the source, the presence of oil in boiler water is undesirable. Oil can act as a binder to form scale. In high heat-transfer areas oil can carbonize and further contribute to the formation of scale and low ph. Foaming is one indication of oil in boiler water. Its presence can also be confirmed by first shaking a bottle containing boiler water. If oil is present foam will result. Often oil in boiler water will originate in the condensate. This contaminated condensate should be directed to the sewer until the source of the oil is determined and corrective steps taken.

31 Iron (oxides): Iron in any of its oxide or complex forms is undesirable in boiler water. Iron in its various forms can originate in the raw water makeup, condensate return water, or form directly in the boiler as a result of corrosion. It can concentrate in the boiler and it tends to collect in stagnant areas. Water Hardness: Water hardness is the measure of calcium and magnesium content as calcium carbonate equivalents. Water hardness is a primary source of scale in boiler equipment. Hardness is removed by softening. Periodically, the ion exchange resin bed requires regeneration by flushing through with a brine solution followed by rising with fresh water. The interval between regeneration is dependent upon the raw water hardness and flow rate. In all cases the water hardness should be tested periodically and prior to starting the generator to ensure efficient operation of the softener. Unsoftened water should not be allowed to enter the steam generator unless sufficient scale inhibitor chemical is used. Feedwater: Feedwater is the combination of fresh makeup and returning condensate that is pumped to the boiler. INSTALLATION - 2 Condensate: Condensate is condensed steam that is normally low in dissolved solids. Hence, it does not contribute to the dissolved solid content of the feedwater. In addition, condensate is very expensive to waste. It s been chemically treated, heated, pumped, converted to steam, and condensed. Dissolved Solids: Dissolved solids are salts in the water that stay in solution. They are invisible to the naked eye. As the boiler generates steam, dissolved solids will concentrate. If the concentration becomes too high, they will precipitate, form a suspended solid, and concentrate in the vessel. Daily boiler blowdown is recommended to help prevent the formation of deposits. Consult Blowdown procedure in the Daily Maintenance Schedule section of this manual. Chemical Dosing: In addition to softening the feedwater, it is also important to consider other factors such as dissolved oxygen and acidity. Depending on the results of an analysis, it may be necessary to inject appropriate amounts of corrective chemical into the feedwater system. This is usually achieved by means of a chemical compound solution and variable output metering pump mounted at the storage vessel. It is important that the chemicals and quantities are correct and it is advisable to contact a water treatment company to arrange a feedwater analysis. 2.8 Piping Specifications For piping the basic considerations are: the design temperature, the pressure retained by the pipe, the fluid in the pipe, the load resulting from thermal expansion or contraction, impact or shock loads imparted (such as water hammer, external loads, wind loads and vibration from equipment). Adhere to the following: 1. The arrangement of the piping and its appurtenances must take into consideration the location of other structures and equipment adjacent to the piping. The potential for freezing interference and/or damage as a result of expansion, contraction, vibration, or other movements must be factored. 2. Valves are used in piping systems to stop and start the flow of fluids, to regulate flow, to prevent back flow, and to relieve excessive pressure build-up in the piping. Consideration should be given to the appropriate location and orientation of valves necessary for safe operation and isolation of the piping. 3. All piping and piping components used should be suitable for the design temperatures, pressure and fluid used in the system. 4. During the installation, ensure that no dirt, water, or residue from welding is left in the system. 5. Expansion joints or properly designed and sited loops should be provided to accommodate thermal expansion. Thermal expansion should be calculated using the maximum possible utilization fluid temperature, regardless of whether the pipe considered is in the feed or return circuit. Steel pipe will expand approximately 1 mm per meter over 100 C rise. Page 23

32 INSTALLATION - 2 Fulton Ltd 6. Supports and anchors must be provided for all pipes, as necessary, to prevent undue stresses from being placed on equipment, including pumps, valves, and the boiler. Supports and anchors which will not interfere with thermal expansion should be chosen. The equipment should never be used or considered as an anchor. No additional loads should be applied to any factory connection. 7. Gaskets must be used to make all flanged connections. Gasket material must be suitable for use with the pressure, temperatures and fluids in the system. Ensure that all bolts are tightened evenly and to the torque recommended values provided by the gasket manufacturer. 8. High point bleeds/air vents are to be installed at all high points in the system piping. 9. All pipes should be installed with a pitch to facilitate draining and venting. 2.9 Insulation! WARNING After the appropriate system tests have been satisfactorily completed, all hot pipework and vessels must be adequately insulated with material suited to the temperature and application to prevent both heat loss and personnel injury. Note: It is recommended that for inspection and maintenance, pumps, flanges, valves and fittings be left uninsulated but suitably shielded for safety. Adhere to the following: 1. Return tanks, surge tanks and deaerators should be insulated. Insulation should be chosen with care such that the fluid in the tanks does not exceed the maximum operating temperature of the pump. 2. Blowdown vessels should not be insulated. 3. Equipment should be insulated with material suitable for the application and temperatures expected Pipework leak/pressure Tests Upon completion of the installation, adhere to the following for system piping testing: 1. Perform a pneumatic test not exceeding 15 psig. 2. Perform leak spray tests at all welds and joints to ensure that the system is free from leaks. Page 24

33 COMMISSIONING - 3 SECTION 3 - COMMISSIONING 3.1 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. Main air adjusting screw 6 mm Peep hole Main air adjustment plate Main flame observation glass Primary / Secondary air adjustment Note: Air adjustment controls are only found on non-modulating burners. Figure Air Adjustment Page 25

34 COMMISSIONING - 3 Fulton Ltd Boiler Inspection And Initial Firing DUAL FUEL Burner Burner Plate NOTES: 1. GAS ELECTRODE TIP SHOULD BE POSITIONED 3mm FROM THE END OF THE GAS SUPPLY PIPE TO ENABLE IGNITION. 2. OIL ELECTRODE TIP SHOULD BE POSITIONED 3mm FROM ONE OF THE OIL NOZZLES Gas Ignition Electrode Oil Ignition Electrodes dimensions in mm Figure Basic Burner Electrode Assembly (DUAL FUEL) Mains gas supply Pilot gas supply Flame detector Ignition electrodes Figure Ignition Flame Detector (DUAL FUEL) Dual fuel boilers that use a common burner assembly and have a switch change over from one fuel to another, have to be commissioned on the basis of a primary fuel (usually gas), with the secondary fuel as a back-up. The secondary fuel then has to be commissioned using the air settings for the primary fuel. In practice this means adjusting the fuel input of the secondary fuel to achieve acceptable combustion. As more air is required for oil combustion the consequences are that when oil is the secondary fuel there will be a small reduction in the fuel input rate. Page 26

35 COMMISSIONING Boiler Inspection And Initial Firing Gas Burner Main Gas Supply Ignition Electrode Flame Ultraviolet sensor/photocell Detector mm Primary Air Blast Tube 12.7 mm 3 mm min. 5 mm max 50.8 mm Figure Gas Burner Electrode Settings 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 bottle and the boiler shell and record their lengths. Replace any damaged probes. 2. Remove the burner and check the electrodes have not been damaged and that their settings are correct. If the burner is fitted with a flame detector, remove it and check for damage. 3. Check that the burner is the correct type for use with the gas being supplied. 4. Replace the burner and reconnect the gas connection (and the copper oil line(s) to the oil nozzle assembly on Dual Fuel burners), ensuring these connections are tight. Reconnect the ignition leads and replace the flame detector. 5. (DUAL FUEL ONLY) Ensure that the oil supply isolation valve is closed. Check that the gas supply valve is open. 6. Ensure that all wiring connections are correct and that all terminal screws are tight. 7. A barometric type draught stabiliser, if fitted in the flue, should be set for a draught of mbar to mbar of water bottle pressure with the burner off. 8. 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. Open the isolating valve on discharge side of feedwater pump. CONTINUED ON NEXT PAGE Page 27

36 COMMISSIONING - 3 Fulton Ltd 9. Check the correct rotation of the feedwater pump on the motor fan cover. Start the feedwater pump and check the direction of rotation. DO NOT ALLOW THE PUMP TO RUN DRY. 10. Open all the valves in the water feed line. Switch on the feedwater pump motor and fill the boiler (see Section Filling 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. 11. Open the boiler blowdown valve and slowly drain the boiler. When the water level falls below the PUMP ON probe, the pump should start. If the pump does not start, check the probe connections. 12. Close the boiler blowdown valve.! WARNING Gas purging by qualified persons only. 13. After purging the gas lines of air, start the burner as detailed in Section Boiler Start-Up. For models 40J - 60J with an external pilot gas line, see Section 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. 14. After the burner has been firing for approximately five minutes, adjust the gas and main air control gate located on the burner scroll, to obtain a clean combustion. Measure the levels of CO 2 CO and O 2 in the exhaust gas and record the results. See typical combustion values given in Appendix A - TI Observe the flame through the observation glass and adjust the primary/secondary air control located on the top of the boiler, so that the flame can be seen passing down the blast tube. 16. Check the operation of the low water safety controls (see Section Low Water Level Check). 17. Adjust the steam pressure control to suit the boiler application (see Section Steam Pressure Controls). 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 28

37 COMMISSIONING Boiler Inspection And Initial Firing OIL Burner High fire oil supply Low fire (start) oil supply Burner plate Electrodes Electrodes View on arrow A 12 mm 5 mm 130 mm Electrode settings relative to nozzles Electrode tips bent to align with low flame (Start) oil supply nozzle Arrow B 300 mm 5 mm 5 mm Fuel Nozzle 80 Spray 300 mm Nozzle manifold High fire oil supply 80 spray Arrow A 5 mm Low fire oil supply DOUBLE NOZZLE TWO-STAGE LIGHT 40J - 60J 12 mm View on arrow B 12 mm SINGLE NOZZLE SINGLE-STAGE LIGHT 10J - 30J Figure Nozzle and Ignition Assemblies (OIL ONLY) Note: Always place the highest value nozzle (engraved on the side of the nozzle) into the low fire oil supply port in the manifold. 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 bottle and the boiler shell and record their lengths. Replace any damaged probes. 2. Remove the burner and check the electrodes have not been damaged and that their settings are correct. If the burner is fitted with a flame detector, remove it and check for damage. 3. Replace the burner and reconnect the copper oil line(s) to the oil nozzle assembly (and gas connection on Dual Fuel burners), ensuring these connections are tight. Reconnect the ignition leads and replace the flame detector. CONTINUED ON NEXT PAGE Page 29

38 COMMISSIONING - 3 Fulton Ltd 4. (DUAL FUEL ONLY) Ensure that the gas supply isolation valve is closed. Check that the oil supply valve is open. 5. Check the rotation of the oil pump motor. Ensure that the oil supply flow and return valves are open. Bleed the oil pump. 6. Ensure all wiring connections are correct and that all terminal screws are tight. 7. A barometric type draught stabiliser, if fitted in the flue, should be set for a draught of mbar to mbar of water bottle pressure with the burner off. 8. 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. 9. Check the correct rotation of the feedwater pump on the motor fan cover. Start the feedwater pump and check the direction of rotation. DO NOT ALLOW THE PUMP TO RUN DRY. 10. Open all the valves in the water feed line. Switch on the feedwater pump motor and fill the boiler (see Section Filling 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. 11. Open the boiler blowdown valve and slowly drain the boiler. When the water level falls below the PUMP ON probe, the pump should start. If the pump does not start, check the probe connections. 12. Close the boiler blowdown valve. 13. Fit oil pressure gauge to oil pump to verify oil pressure. 14. Start the burner as detailed in Section Starting the burner. Allow time for the fuel pump to prime itself. 15. After the burner has been firing for approximately five minutes, adjust the main air control gate located on the burner scroll, to obtain a clean combustion. See typical combustion values given in Appendix A - TI Observe the flame through the observation glass and adjust the primary/secondary air control located on the top of the boiler, so that the flame can be seen passing down the blast tube. 17. Check the operation of the low water safety controls (see Section Low Water Level Check). 18. Adjust the steam pressure control to suit the boiler application (see Section Steam Pressure Controls). 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 30

39 COMMISSIONING Setting the Burner Controls GAS Burner 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 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. Page 31

40 COMMISSIONING - 3 Fulton Ltd 3.3 Gas Monoblocs Non Modulating Burner Setting the gas pressure switch. - Models Remove the adjustable gas pressure switch cover. 2. Set the pressure switch by rotating the setting wheel to the desired pressure. Normally set to 2.5 mbar below the normal supply pressure with the boiler running. Setting the pressure regulator. - Models Remove the regulator cover. 2. Using a screwdriver, set the regulator to the desired pressure: Clockwise to increase pressure. Anticlockwise to decrease pressure. Gas pressure can be tested at the test point on top of the gas output flange. Setting the main gas flow (V2) - Models factory set, would not normally be altered. 1. Loosen the security screw on the setting plate. 2. Turn the setting plate: Clockwise to reduce gas flow. Anticlockwise to increase gas flow. Rapid stroke adjustment Model factory set, to slowest possible opening, would not normally be altered. 1. Unscrew the adjustment cap from the hydraulic brake. 2. Invert the cap and use as a tool: Clockwise = slowest opening time. Anticlockwise = fastest opening time. Page 32

41 COMMISSIONING Multi Bloc Gas VALVES Main gas line isolating valve Pilot line isolation ball valve Pilot line governor Pilot line gas valves Main gas valve assembly Figure J - 60J Gas Valve (non modulating burner) Gas actuator Gas governor Gas valve Figure J - 60J Gas Valve (fully modulating burner) Page 33

42 COMMISSIONING - 3 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 downstream of Valve 2 Test point connection upstream of Valve 1 Output pressure controller adjusting screw Operating indicator Hydraulic brake Main gas flow adjustment Adjustable pressure switch Test point connection downstream of Valve 1 Gas input flange Gas input filter cover Test point connection downstream of Valve 2 Test point connection upstream of Valve 1 Figure. 23-6J - 30J Gas Valve (non modulating burner): Major Components Page 34

43 COMMISSIONING - 3 Hydraulic brake Main gas flow adjustment Output pressure controller adjusting screw Operating pressure indicators High fire solenoid Low fire flow adjustment Input gas test point Adjustable pressure switch Gas input mounting flange location Test point 1 downstream (internal leak test) Test point 2 downstream Test point 1upstream Figure J - 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 J - 60J Gas Valve (fully modulating burner): Major Components Page 35

44 COMMISSIONING - 3 Fulton Ltd 3.4 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. Page 36

45 OPERATION - 4 SECTION 4 - 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. 4.1 General The following instructions are given for the guidance of the operator in the use of the J Series fuel 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. 4.2 Controls The following brief description of the controls used on the J series fuel 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. Page 37

46 OPERATION - 4 Fulton Ltd Boiler Controls Note: All the limiters are of the fail-safe type and are wired in series; failure of any one will automatically shut down the boiler. Low Water Limiters, Feedwater Pump Relay and High Water Level Relay These limiters and relays operate in conjunction with probes suspended in the boiler and water bottle 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, or if an unsafe water level is achieved. Steam Pressure Controls The steam pressure controls vary depending on the type of boiler control utilised. The controls are located on the side of the control panel box and are connected to the steam pressure gauge assembly by copper tube. An operating pressure switch controls the on/off cycle of the burner, shutting the burner off when maximum operating pressure is reached and switching it on when the steam pressure falls. A High/Low pressure switch may be fitted which switches the burner between a high flame and a low flame which allows the burner to continuously run rather than switching it on & off. An operating pressure transducer replaces the operating pressure switch for a modulating control. Note: A set-back pressure controller is fitted when multi-boilers are fitted with a sequence control. 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. Fuel Pump (OIL) Mounted on the burner scroll and driven by the burner motor, the fuel pump delivers oil to the burner nozzles at the correct pressure to allow complete atomisation and therefore combustion. 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. Page 38

47 OPERATION Boiler Control Panel 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 power on 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. Power On Indicates that power is being supplied to the control panel box. Pump OFF/ON This switch isolates the feedwater pump and must be switched ON before switching on the Boiler OFF/ON switch. This functions as a pump interrupt switch. Boiler OFF/ON This switch isolates the burner and must be switched ON to initiate burner start-up. Low Water Limiter 1 This light will energise when the boiler water is below low limiter 1. The light will illuminate, a continuous alarm will sound and the burner will go to lockout. Once the water in the boiler has been restored to a safe operating level, pressing the Common Alarm Reset button will reset the controls and allow the burner start sequence to initiate. Low Water Limiter 2 This light will energise when the boiler water is below low limiter 2. The light will illuminate, a continuous alarm will sound and the burner will go to lockout. Once the water in the boiler has been restored to a safe operating level, pressing the Common Alarm Reset button will reset the controls and allow the burner start sequence to initiate. High Water Level Indicates high water level in the boiler, isolates the feedwater pump and sounds an alarm. Once the water in the boiler has been returned to a safe operating level, the light will go out and normal control is resumed. High Steam Pressure This light indicates when the boiler pressure exceeds the maximum allowable pressure. The high pressure controller can be reset using the switch on top of the controller. Ignition Indicates that the ignition transformer has been energised. This light will only be illuminated for approximately 5-10 seconds during the ignition sequence. Low Gas Pressure 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. Main Gas This light illuminates when the Multi-bloc gas valve is energised. Pilot Gas (40J - 60J models) This light indicates the gas valves in the pilot line are energised. CONTINUED ON NEXT PAGE Page 39

48 OPERATION - 4 Fulton Ltd Gas Valve CPI (closed position indicator) The valve switch is located on the main gas valve. This is monitored by the burner controller and shows a green indicator when the valve is closed. Burner Fan This light indicates that the burner motor contactor is energised. Burner Alarm This light will illuminate when the burner has gone to a lock-out condition due to flame failure. The burner controller can be reset by pressing the Common Alarm Reset button.! WARNING No more than two attempts should be made to start the boiler by resetting the burner alarm. Further attempts could cause the boiler and flue system to fill with vaporised oil which could cause an explosion. Oil Pump Running This light will illuminate when the oil pump is running. Stage 1 Oil This light provides a visual indication that the magnetic oil valve for start-up oil supply has been energised. Stage 2 Oil This light provides a visual indication that the magnetic oil valve for operating oil supply has been energised. TDS Alarm This light will illuminate when a high level of TDS is detected in the boiler. A boiler blowdown may be required to correct the TDS levels. Pressing the Common Alarm reset button will reset the alarm when the TDS level is corrected. Common Alarm Reset Pressing this button will clear rectified alarms. This light will extinguish when all alarms are rectified. Alarm Mute Pressing this button will silence the audible alarms but will not clear them. Alarms must be checked and rectified. 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. Selector Switch GAS/OIL This switch is to select the fuel input type to be used. The boiler must be switched off before changing fuels. For further details, see Section 4.3 Changing To The Alternative Fuel. Oil Firing This light will illuminate when the Selector Switch GAS/OIL is set to OIL. Gas Firing This light will illuminate when the Selector Switch GAS/OIL is set to GAS. Page 40

49 OPERATION - 4 Low Fire Hold OFF/ON This switch is used to maintain the boiler in low fire mode during commissioning Remote Panel Disable (inside boiler panel) Pressing this button will disarm the remote alarm panel to avoid nuisance remote alarms whilst maintenance is undertaken. Figure Control Panel (GAS J High Low Arrangement 3) Figure Control Panel (OIL J On Off Arrangement 3) Page 41

50 OPERATION - 4 Fulton Ltd Figure Control Panel (Dual Fuel J High Low Arrangement 3) Steam Pressure Controls Pressure controls are mounted on the side of the control box. Pressure controls are as follows: Operating Pressure Switch (On/Off) Controls the ON/OFF cycle of the burner, switching the burner off when the desired steam pressure is reached and switching it on when steam pressure falls. High/Low Operating Pressure Switch Allows the burner to continuously operate between limits by switching the control from high flame to low flame as required. If the pressure goes outside of the limits then the standard operating pressure switch will then operate to turn the burner on & off as required. Operating Pressure Transducer Replaces Operating Pressure Switch. Sends a signal to the load controller to control the operating pressure in the boiler by modulating the burner output and turning the burner off when max operating pressure is achieved. High Pressure Limiter Should the operating Pressure Switch fail, the steam pressure will raise above the pre-set limit causing the High Pressure Limiter (set at least 0.5 barg higher than the Operating Pressure Switch) to switch off and lock out the burner. A High Steam Pressure Indicator will illuminate and an alarm will sound. Should this happen, switch the Boiler OFF/ON switch to OFF and wait until the steam pressure is discharged. Check the connection to the pressure switch, replace as required. CONTINUED ON NEXT PAGE Page 42

51 OPERATION - 4 Operating Pressure Transducer Operating Pressure Switch High/Low Operating Pressure Switch High Pressure Limiter High Pressure Limiter Figure Pressure Control (modulating) Figure Pressure Control (on/off & High/Low) Setting Pressure Controls 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 (see Appendix D). Page 43

52 OPERATION - 4 Fulton Ltd Testing Steam Pressure Controls 1. Start the boiler. 2. Shut the main steam valve. 3. Set the Operating Pressure switch to its maximum. 4. Set the High Pressure Limiter to 0.5 barg below the safety valve setting. 5. Allow the steam pressure to rise until the high limit pressure switch trips. On the steam pressure gauge, check that the pressure is not less than 0.5 barg below the safety valve lift pressure. If the pressure is incorrect, repeat steps 2, 4 and Open the main steam valve slowly to lower the steam pressure. 7. Reset the operating pressure switch to the required working pressure and the high/low pressure switch to 0.3 barg barg below the operating pressure switch setting. 8. Shut the main steam valve. 9. Reset the high pressure limiter and allow the steam pressure to rise until the high/low pressure switch reduces the burner to low fire, and then the burner shuts down under the Operating Pressure switch. 10. Readjust if necessary to achieve the required settings. Note: The requirement for a difference between the operating and high pressure limiter is to prevent unnecessary high steam pressure faults tripping the burner at no load conditions. The residual heat in the furnace, the flue pipes and the door refractory is capable of raising steam pressure slightly, causing the high pressure limiter to trip out. 4.3 Changing To The Alternative Fuel Dual Fuel Burner 1. Switch OFF the electrical supply at the door isolator switch. 2. Isolate the supply lines of the fuel not required. 3. Open the isolation valve on the required fuel supply. 4. Switch the fuel selector switch to the required fuel. 5. Switch ON the electrical supply to the boiler at the door isolator. 6. Start the burner. Page 44

53 OPERATION Filling the BOILER ALL models 1. The door isolator should be in the OFF position. 2. Ensure the Boiler and Pump Switches are in the OFF position. 3. Ensure the following valves are Open: a) Main steam stop valve. b) Steam pressure gauge isolating valve. c) All valves in the feedwater line. d) Water level gauge (sight glass) isolating valves. 4. Ensure the following valves are Shut: a) Main blowdown valve. b) Water level gauge blowdown valves. c) Water bottle blowdown valve 5. Select the fuel to be used, ensure that the valves in the selected fuel line(s) are open, and the alternative fuel lines are closed (see Section Changing To The Alternative Fuel).! 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. 6. Vent the pump. 7. Turn the door isolator to the On position. 8. Turn the Pump switch to the ON position. 9. The feedwater pump should start (check the pump direction of rotation) and fill the boiler to the correct working level and then automatically switch Off. 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). Note: It may be necessary to vent the feedwater pump by bleeding air from the plug mounted in the top casting below the pump motor to pump body connection. Page 45

54 OPERATION - 4 Fulton Ltd 4.5 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 pumps. 4. Open the main steam valve and the boiler drain valve. 5. Open the blowdown vessel drain valve. 6. Open all valves in the drain lines. (Skid Units/Plant Rooms, have internal drainage systems which require the same procedures). Boilers with automatic blowdown systems 1. The boiler should not be under pressure. The boiler should be cold. 2. Open the main blowdown valve. 3. Using the blowdown bypass valve to throttle the flow, drain the boiler. Note: Skid units and plant rooms have internal drainage systems which require the same procedures. If a blowdown bypass valve is not fitted then you can manually blowdown the boiler by using a flat-head screwdriver. Locate manual blowdown button (labelled as A in Figure. 31), push the Manual Blowdown Button up and make a quarter turn clockwise, this will lock the button in position and open the blowdown valve. Main blowdown valve Automatic blowdown valve A Blowdown bypass valve Figure Automatic Blowdown Valve Page 46

55 OPERATION Boiler Start-Up (from cold) ALL models 1. Fill the boiler (see Section Filling The Boiler). 2. Ensure the main steam isolating valve is Shut. 3. Open all the valves in the gas train/oil supply. It is assumed that the fuel supply lines have been purged prior to attempting to start the boiler/burner.! CAUTION Failure to open the oil supply line will damage the oil pump. A pump damaged under these circumstances will not be replaced by warranty. 4. (DUAL FUEL ONLY) CLOSE alternative fuel supply valves with the proof of closure microswitch. 5. Switch the Pump and Boiler switches to the ON position. The Low Water audible alarm will sound, the Low Water Limiter lights will illuminate. 6. Press the Common Alarm Reset button for two seconds maximum. The alarms will stop, and the alarm lights will extinguish. Reset high pressure switch. The burner start sequence will commence. 7. After a maximum of two minutes the burner should be firing, and the Main Gas light should illuminate. 8. 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. This can be achieved by one of two methods:! CAUTION The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock and water hammer. a) Partially 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. Note: Before leaving the boiler unattended, the daily operating tests (see Section 5.8.1) should be carried out to check the functions of all the safety interlocks. Page 47

56 OPERATION - 4 Fulton Ltd Boiler Start-Up Following Short Term Shut-Down If the boiler has been shut-down short term (see Section Short Term Shut-Down), the large thermal mass in the boiler will maintain the internal temperature to a point that the boiler can be simply switched on (preferably on low fire) and then left to reach working temperature/ pressure. 4.7 Boiler Shut-Down Short Term Shut-Down (hours) Switch Boiler switch to OFF on the boiler control panel switch. The burner will stop firing, post-purge and then stop Medium Term Shut-Down (days) 1. Shut the main steam valve. 2. Leave Pump switch ON. 3. Switch Boiler switch OFF. 4. Shut off fuel supply. Note: Ensure the boiler water treatment levels for dissolved oxygen are within the specified limits Long Term Shut-Down (weeks) To store the boiler in a corrosion-free situation there are two practical solutions: 1. Fully flood the boiler to exclude as much air as possible. 2. Drain the boiler completely. Remove all hand holes. Open all gas/oil side access doors. Additionally you could introduce a form of convection heating to the gas/oil and water side. A very effective solution is to install a small heater. Page 48

57 MAINTENANCE - 5 SECTION 5 - 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. 5.1 Boiler Platform (if Fitted) Platforms are designed to allow easy maintenance access to the components on the top of the boiler (i.e. the water level probes, main steam valve, vent and safety valves). It is the responsibility of the user to ensure that a site risk assessment is carried out for the safe use of ladders and working at height on the platform. 5.2 Visual Checks Inspect the steam and feedwater pipework, valves and fittings for signs of leakage. If leaks are suspected, shut-down 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. Page 49

58 MAINTENANCE - 5 Fulton Ltd 5.3 Burner 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 plug-in connection on the top of the burner. 3. Cover the sensor glass to exclude all light. 4. The burner control should go to a lockout/flame failure condition (2-3 sec gas, 34 sec oil) and will require manual resetting. Note: 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. Clean the UV photocell before replacing it. 6. Press the Common Alarm Reset button. 7. Check the burner automatically starts up and fires. Flame sensor Flame sensor Figure Flame Sensor Removal (GAS) Figure Flame Sensor Removal (DUEL FUEL) Flame sensor Figure Flame Sensor Removal (OIL) Page 50

59 MAINTENANCE WATER Level and Low WATER Safety Control Procedures The following procedures ensure the correct functioning of the water level controls and the low water safety controls Feedwater 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. 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. Page 51

60 MAINTENANCE - 5 Fulton Ltd 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 the Pump switch to the OFF position. 3. Allow the water level to lower by natural evaporation below the Low Water level. Do not allow the water level to drop below the bottom of the water level gauge (sight glass). 4. Check: a) Low Water limiter lights illuminate b) Low Water audible alarm sounds c) Burner stops firing d) Feedwater pump does not start If the test fails, turn the boiler off and ensure that the fault is rectified before the boiler is used. 5. Switch the pump switch to the ON position. 6. Check: a) Feedwater pump starts and refills the boiler b) Water level rises above the Low Water level c) Burner does not start d) Low Water audible alarm continues to sound 7. Press the Common Alarm Reset switch for 2 seconds maximum 8. Check: a) Low Water Limiter lights extinguish b) Low Water audible alarm silences c) Burner automatic fire sequence starts 9. Verify that the pump continues to run until the Pump Off level is reached and then switches off Evaporation Check This check may be required by your insurance inspector as part of the annual inspection. To perform the evaporation check, follow the procedure in Section Low Water Level check allowing water to lower by natural evaporation and not by manual blowdown. Page 52

61 MAINTENANCE Blowdown Procedures Keep the boiler, water level gauge (sight glass), water bottle 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 Main Boiler Blowdown (manual) 1. Start the boiler and generate 10 psi of steam pressure. 2. Shut off both the boiler and the pump. 3. Fully OPEN the boiler main blowdown valve for 5 seconds, or as recommended by the water treatment specialist. 4. CLOSE the main blowdown valve. Note: Where high levels of suspended solids are produced, longer and/or more frequent blowdown may be required. Note: Where Auto blowdown is fitted, this blowdown will be carried out automatically on a daily basis. Figure Main Boiler Blowdown Valve WATER Bottle Blowdown Note: The water bottle contains the pump ON/OFF probe, which is not safety interlocked. 1. Switch the Pump switch OFF. 2. Open the water bottle blowdown valve for 5 seconds. 3. Close the water bottle blowdown valve and wait for 10 seconds for the boiler to refill and the water to stabilise in the vessel. 4. Switch the Pump switch to ON. Figure Water Bottle Blowdown Valve Page 53

62 MAINTENANCE - 5 Fulton Ltd WATER Level Gauge (Sight Glass) Blowdown 1B 2B 1B 2B 1B 2B 1A 1C 2C 2A 1A 1C 2C 2A 1A 1C 2C 2A Figure Water Level Gauge (Klinger Sight Glass) Operating Positions Blowdown the water level gauge (sight glass) set 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 (B and C) are OPEN and all blowdown valves (A) are CLOSED. The level gauge isolation valves are equipped with an internal ball check. In the event that a sight glass should break, the ball will set, preventing discharge of steam and water. The valve stem must be opened fully to enable this feature. If the valve is in any other position, the ball will not seat. Note: Where a boiler is operating continuously at steam pressure, advice should be taken from Fulton Ltd as to the appropriate blowdown procedure Note: If your boiler is fitted with Clifton Reflex Gauges instead of Klinger, then handles 1B and 1C will open away from the gauge instead of towards the gauge. Page 54

63 MAINTENANCE Boiler 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. Hand Hole Cover Plate Gasket Crab New gaskets must be fitted every time a hand hole door is removed (see Section Fitting New Gaskets To Boiler Inspection Holes). 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. Figure Hand Hole 5.7 Fitting New Gaskets To Boiler Inspection Holes Important Information! CAUTION TOPOG-E gasket have a finite life after installation and must be renewed annually. It is important that the instructions given in this section are adhered to. The J series boilers are fitted with TOPOG-E gaskets in all the inspection holes of the boiler. These gaskets work very well and millions have been safely used over the last 30 years, however, it is absolutely essential to observe a few simple rules in order to get the best performance from your installation. Elastomeric Vulcanizates, which form the basis of TOPOG-E gaskets, undergo degradation from many sources including heat, oxygen, stress, and overdosing from certain types of water treatment. This takes the form of material oxidation, hardening/embrittlement and cracking which may result in gasket failure. Steps must be taken to minimise the effects of such attacks. Water treatment and oxygen attack can be minimised by ensuring that the gasket is aligned correctly so that only the extreme edges of the gasket are exposed. If a new gasket leaks after fitting this is almost certainly due to incorrect seating or alignment. As such gaskets are very flexible it is possible to cure the leak by excessive tightening, but such an action will seriously reduce the life of the gasket and cause problems later. Undue stress can be avoided by tightening just sufficiently to stop any leakage when fitting cold and before firing the boiler. Start the boiler and gradually bring it up to working temperature, allowing the increasing steam pressure to take over and complete the seal. This will allow the gasket material to contract naturally and follow the topography of the mating surfaces. The securing nut can then be tightened gently by approximately a quarter of a turn, to ensure a snug fit and prevent the seal from being broken when the boiler is cold and under negative pressure. Gentle warming of the boiler on initial firing after maintenance will also help to ensure that the rubber cures to shape. If the rubber post-cures, the elastic memory will be destroyed and any initial over tightening will cause the gasket to become hardened and embrittled, leading to cracks and eventual failure. Page 55

64 MAINTENANCE - 5 Fulton Ltd Fitting Procedure Blowdown the boiler completely (see Section Main Boiler Blowdown) and examine all inspection holes in the boiler. If any leakage is evident, proceed as follows: 1. Disassemble the crab and cover plate and remove the inspection hole assembly. Remove the old gasket and thoroughly clean the mating faces of the cover plate and boiler ring. 2. Place the new Topog-E gasket on the cover plate, ensure the gasket is the correct size and is seating flat against the plate. Do not use any grease, lubricant or adhesive. If the new gasket is not seated properly before the plate is tightened, the gasket may be pinched causing a failure when the pressure builds up. 3. Position the cover plate in the boiler ring, ensuring that the plate is correctly centred. An off centre cover plate can concentrate forces on the gasket and cut it in two. The cover plate may also drag on the boiler hole ring and fail to seal as the pressure rises. Set the crab and hand tighten the securing nut(s) sufficiently to provide a snug fit. Tighten the nuts a further quarter of a turn using a spanner. DO NOT OVER TIGHTEN. Note: Ensure the gasket is aligned correctly so that only the extreme edges are exposed to water treatment or oxygen attack. If the gasket is misaligned, over tightening to seal a leak will not prevent subsequent leakage at a later date. 4. Gradually warm up the boiler, allowing steam pressure to make the seal. If the gasket leaks during pressure build-up, tighten the securing nut(s) sufficiently only to stop the leakage. It is important to keep the nuts correctly tightened thereafter, this prevents the vacuum developed by cooling on shut-down from feeding and draining the boiler. Note: New gaskets fitted to inspection holes located along the bottom of the boiler are more difficult to install without leaking. Small particles of scale or sand tend to run down on the mating surfaces after cleaning but prior to assembling. This condition is likely to have occurred if excess tightening is required to stop a leak before warming the boiler. In this event, the best course of action is to drain the boiler and repeat the gasket fitting procedure. Failure to do so will severely reduce the life of the gasket. 5. Clean and inspect each water level gauge (sight glass). If any water leakage is evident, renew the water level gauge gasket. COVER PLATE AND GASKET IN PLACE CORRECT PLACEMENT DO NOT OVER-COMPRESS GASKET COVER PLATE NOT IN CENTRE Figure Fitting a New Topog-E Gasket Page 56

65 MAINTENANCE 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 guarantee. 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 bottle 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. Page 57

66 MAINTENANCE - 5 Fulton Ltd Daily! WARNING All steam pipework, valves and fittings will be very hot. 1. Visually inspect for signs of leakage: a) Steam and feedwater pipework. b) Valves and fittings. c) Hand holes If leakage is evident, the gasket needs replacing. If leaks are suspected, shut down and evacuate the system to atmospheric pressure before attempting to repair the leaks. 2. Low Water Level Check (see Section 5.4.2). Note: Where high integrity level controls are fitted, please refer to Appendix E Spirax High Integrity Level Controls. 3. Blowdown the Boiler (see Section 5.5.1). 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. 4. Blowdown the Water Bottle (see Section 5.5.2). 5. Blowdown the Water Level Gauge (sight glass), (see Section 5.5.3) 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. 6. Ensure that the pipe from the safety valve outlet is not damaged and that it continues to a safe blowdown point. 7. Feedwater Pump Test (see Section 5.4.1). 8. Burner Flame Sensor Test (see Section 5.3). Page 58

67 MAINTENANCE MONTHLY IN addition! WARNING Ensure the main electrical supply is isolated before starting work. 9. Visually inspect the internal water space (see Section 5.6). 10. 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. 11. Clean the water level gauges (sight glasses). If any leakage is evident, the gasket needs replacing (see Section 5.7). 12. 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 Six Monthly Service! WARNING 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. The boiler must be drained and isolated before the following maintenance procedures are carried out (see Section Draining the Boiler). 1. Visually inspect feedwater dip pipe into the boiler. Ensure the pipe is not blocked, clean as required. 2. Clean the ignition electrode. 3. Clean out the flue passes. 4. Inspect stainless steel ring. 5. Apply a small quantity of oil to the bearings of the burner motor and the feedwater pump motor. 6. Clean the burner scroll fan. 7. Remove components from threaded stub pipes, clean and inspect. 8. Rod through top connections of the water level gauge and water bottle. 9. Drain and flush the feedwater tank. Clean any filters in the tank, in the feedwater line or in the feedwater pump. 10. Clean the water level probes. Page 59

68 MAINTENANCE - 5 Fulton Ltd 11. Test the flue using the following procedures: Visual Inspection Smoke Test 12. Check the burner combustion. 13. Check the condition of the gas valve filter (if fitted), renew as required Annual Service! WARNING 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. The boiler must be drained and isolated before the following maintenance procedures are carried out (see Section Draining the Boiler). 14. Inspect the pilot assembly. 15. Clean and examine flue ways and remove loose scale from inside shell. 16. Examine refractory brick. 17. Check all panel wiring connections for conditions and tightness. 18. Refill boiler with water, checking for leaks. 19. Test for gas safety. 20. Check oil pressure or gas flow rate and combustion parameters. Re-commissioning. 21. Refill boiler and re-commission burner check all functional operations of burner and boiler including water safety checks and flame failure procedures. Operate boiler to working pressure and check safety valves for operation and settings. 22. Inspect and clean blowdown separator if part of installation After 5 Years 23. Fulton Ltd recommend replacement of all threaded stub pipes on the boiler OR to your inspectors satisfaction After All Repairs & MAINTENANCE IN addition 1. Complete all safety checks in the daily and weekly maintenance section. 2. Fire the boiler and perform combustion safety checks. 3. Analyse combustion throughout the range and verify proper operation of safety devices. Page 60

69 MAINTENANCE Maintenance Record Keeping Boiler log sheets should be completed on a regular basis, this provides invaluable information in the subsequent investigation of the boiler history. Maintenance log sheets can be found in the Fulton boiler Log Books provided by Fulton. To Purchase a Fulton Boiler Log Book, please contact training@fulton.co.uk. Vertical Steam Boiler - Daily and Weekly Tests DAILY TESTS Date 1. Visual Inspection of pipework, fittings and hand holes for signs of leakage. Y - N Y - N Y - N Y - N Y - N Y - N Y - N 2. Low Water Level Check - low water indicator illuminate, alarm sound and burner cuts-out. Y - N Y - N Y - N Y - N Y - N Y - N Y - N 3. Blowdown, Boiler 4. Blowdown, Water Bottle 5. Blowdown, Water Level Gauge 6. Pressure gauge reading for blowdown tests. Duration seconds. Test Time. Duration seconds. Test Time. Duration seconds. Test Time. Boiler water and water treatment values must be within known tolerances of the datum. 7. Boiler Water. datum value. TDS. reading datum value. PH reading 8. Oxygen Scavenger Concentration datum value. reading 9. Brine level correct Y - N Y - N Y - N Y - N Y - N Y - N Y - N WEEKLY TESTS Flame Sensor Test Y - N 11. Feedwater Pump Test - Feedwater pump, start/stop Y - N 12. Safety valve outlet pipe to safe blowdown point and free of damage Y - N Test results and actions taken Day 1. sig. Day 5. sig. 2. sig. 6. sig. 3. sig. 7. sig. 4. sig. 7+. sig. Log examined by: Date: Model: Boiler Number: EXAMPLE Fuel: MAINTENANCE LOG Date Time Operation Performed Remarks Operators Initials EXAMPLE Page 61

70 MAINTENANCE - 5 Fulton Ltd Page 62

71 TROUBLESHOOTING - 6 SECTION 6 - TROUBLESHOOTING 6.1 Troubleshooting Gas boiler Problem Cause Remedy 1. Ignition Failure 1. Gas supply Check for gas pressure and intermittent supply problems. 2. Flame Failure During Start-up 2. Power Supply Check fuse or circuit breaker. Reset or Replace as required. 3. 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. 4. Transformer Check voltage between transformer leads at terminal block to be sure transformer is live. 5. UV Detector Check for ignition interference. 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. Air Settings Check main air adjustment and secondary air adjustment. 8. Faulty Air Switch Check for faulty air switch. 9. Gas Valve Check filters in the valve block. Clean as required. 10. Loose wire connections Check connections to all components. 1. Gas supply Check for gas pressure and intermittent supply problems. 2. Power Supply Check fuse or circuit breaker. Reset or Replace as required. 3. Air Settings Check air adjustment. Air may be blowing flame away from the UV detector. Open primary air until fire brushes the furnace wall. 4. 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. 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 circuit. Tighten wiring connections. 8. Contact open on Air Switch Adjust to the correct setting. 9. UV Detector wiring reversed at Change to the correct terminals. control box. Page 63

72 TROUBLESHOOTING - 6 Fulton Ltd 6.1 Troubleshooting Gas boiler Problem Cause Remedy 3. Flame Failure During Normal Run 1. Power Supply Check fuse or circuit, reset or replace as necessary. 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. 4. Boiler fails to start 1. No Power Check fuse or circuit breaker. Reset or replace as necessary. 2. Pressure Control Disconnect all power to the controller. Disconnect the wires from the controller. Connect an ohmmeter between the switch terminals. Lower the set point of the controller, the switch should make. Raise the set point and re-check, switch should break. if the controller operates improperly, replace it. 5. Burner Cut-off 1. 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. 2. Power Supply Check fuse or Circuit breaker. Reset or replace as required. 3. 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. 4. UV Detector Check the detector is located correctly and clean. 5. Faulty Air Switch Check for faulty air switch by jumpering the two air switch leads at the terminal block. If the boiler starts and runs with the jumper in place, the air switch should be replaced. 6. Faulty Level Control Check the level control relays are securely mounted on their bases. Check the power supply to each. The relays may be checked by swapping positions and checking they are both functioning. 7. Weak Pilot Adjust to larger pilot by adjusting pilot gas pressure regulator. 8. Transformer Check voltage between transformer neutral at terminal block to be sure transformer is being powered. 9. Burner Control Check voltage between pilot terminal and neutral and ignition terminal and neutral. Check must be made before the control locks out on safety. If no power replace control. 10. Pressure Control Disconnect all power to the controller. Disconnect the wires from the controller. Connect an ohmmeter between the switch terminals. Lower the set point of the controller, the switch should make raise the set point and re-check, switch should break. If the controller operates improperly, replace it. Page 64

73 TROUBLESHOOTING Troubleshooting Gas boiler Problem Cause Remedy 6. Poor Combustion 1. Refractory bricks Check the bricks are not plugged with soot or broken into pieces. Clean and replace as required. 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 CO 2 and O 2 levels. 5. 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. 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. 7. Burner Back Fires 1. Refractory Bricks Check the bricks are not plugged with soot or broken into pieces. Clean and 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. 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 no exhaust fans are running in the boiler room. 6. Air Settings Check air adjustment. Air may be blowing flame away from the UV detector. Open primary air until fire brushes the furnace wall. 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. 8. Dirty flue Check flue for Carbon build-up or blockage. Clean flue passages with brush. CONTINUED ON NEXT PAGE Page 65

74 TROUBLESHOOTING - 6 Fulton Ltd 6.1 Troubleshooting Gas boiler Problem Cause Remedy 8. Boiler will not maintain pressure 9. Boiler is Surging (Widely fluctuating water level in sight glass) 10. Boiler rumbles and pulsates 11. Boiler carrying over water with the steam 1. 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. If possible meter the flow rate. 2. Dirty flue Check flue for Carbon build-up or blockage. Clean flue passages with brush. 3. Pressure Control Disconnect all power to the controller. Disconnect the wires from the controller. Connect an ohmmeter between the switch terminals. Lower the set point of the controller, the switch should make raise the set point and re-check, switch should break. If the controller operates improperly, replace it. 4. Scale build-up in boiler Clean the pressure vessel. 5. Refractory Bricks. Check the bricks are not plugged with soot or broken into pieces. Clean and replace as required. 6. Steam traps blowing through. Check steam traps, clean or replace as required. 7. Boiler size. Boiler may be under sized for the application. Consult Fulton. 8. Faulty Gas Valve. Check gas flow rate. 1. Steam traps blowing through. Check steam traps, clean or replace as required. 2. 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. 3. Scale buildup or lime deposits. Consult Fulton or call a water treatment specialist. 4. Too much compound (water treatment over dose). Dump contents of the return tank and flush the 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. 1. Poor Combustion Check combustion readings. 2. 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. 3. Too much main air. Adjust main air gate. 1. Steam Traps. Check steam traps, clean or replace as required. 2. Too much compound (water treatment over dose) in the system. Dump contents of the return tank and flush the system. Test the water. 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. Low fuel pressure. 1. Gas pressure regulator Check and replace. CONTINUED ON NEXT PAGE Page 66

75 TROUBLESHOOTING Troubleshooting Oil boiler Problem Cause Remedy Ignition Failure 1. Oil Tank Empty Refill the oil tank. A slight delay in the re-priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily. 2. Power Supply Check fuse or Circuit breaker. Reset or replace as required. 3. Ignition Electrodes Check electrodes for carbon build-up, clean if required. Check settings adjust if required. Check for cracks in porcelain, if found, replace. 4. Transformer Check voltage between transformer leads at terminal block to be sure transformer is live. 5. UV Detector Check for ignition interference. 6. Loose wire connection Check connections to all components. 7. Burner Control Check voltage between pilot terminal and neutral and ignition terminal and neutral. Check must be made before control locks out on safety. If no power, replace control. 8. Oil nozzle clogging Check oil nozzle(s), clean or replace as necessary. 9. Faulty Oil Pump Check to see if oil is being pumped to the boiler nozzle. Repair or replace as necessary. Flame Failure (see note) 1. Power Supply Check fuse or Circuit breaker. Reset or replace as required. 2. Ignition Electrodes Check electrodes for carbon build-up, clean if required. Check settings adjust if required. Check for cracks in porcelain, if found, replace. 3. Main Air Adjustment Check air adjustment. Air may be blowing flame away from the UV detector. Open primary air until fire brushes the furnace wall. 4. UV Scanner Check for dirt on scanner, clean as required. Check for proper location of detector. 5. Contact open on Adjust to proper setting air safety switch. 6. Scanner wiring reversed at Change to correct terminals. panel ` 7. Oil Supply Check oil level in supply tank, ensure it is not below intake line. Fill tank with oil. Check for clogged nozzle. Clean or replace. Check oil filter and replace if necessary. 8. Oil Valve Check the voltage between oil valve neutral at terminal block to be sure oil valve is getting power. 9. Oil Pump Check for clogged strainer or filter. Remove and clean. Check for slipping or broken coupling. Tighten or replace. Check for seized pump shaft. Replace. 10. Loss of Oil Prime Check all lines for possible air leak in intake line and tighten. Check the intake line is not restricted. Replace. Note: One of the most common causes of flame failure is dirt/sediment in the oil filter, oil lines, solenoid valves or nozzle, caused by a new delivery of oil. If the oil tank level is allowed to fall near to the bottom of the tank it is highly probable that sediment on the bottom of the tank will be disturbed and mixed in with the new oil delivery, especially if the delivery rate is too fast. CONTINUED ON NEXT PAGE Page 67

76 TROUBLESHOOTING - 6 Fulton Ltd 6.2 Troubleshooting Oil boiler Problem Cause Remedy Boiler fails to start 1. No Power Check fuse or circuit breaker. Reset or replace as necessary. 2. Pressure Control Disconnect all power to the controller. Disconnect the wires from the controller. Connect an ohmmeter between the switch terminals. Lower the set point of the controller, the switch should make. Raise the set point and re-check, switch should break. if the controller operates improperly, replace it. Burner Cut-off 1. Oil tank empty Refill the oil tank. A slight delay in the re-priming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily. 2. Power Supply Check fuse or Circuit breaker. Reset or replace as required. 3. Ignition Electrodes Check electrodes for carbon build-up, clean if required. Check settings adjust if required. Check for cracks in porcelain, if found, replace. 4. UV Detector Check for dirt on detector, clean as required. Check for proper location of detector. 5. Faulty Air Switch Check for faulty air switch by jumpering the two air switch leads at the terminal block. If the boiler starts and runs with the jumper in place, the air switch should be replaced. 6. Faulty Level Control Check the level control relays are securely mounted on their bases. Check the power supply to each. The relays may be checked by swapping positions and checking they are both functioning. 7. Oil Nozzle Check for clogged nozzle, clean or replace. 8. Transformer Check voltage between transformer neutral at terminal block to be sure transformer is being powered. 9. Burner Control Check voltage between pilot terminal and neutral and ignition terminal and neutral. Check must be made before the control locks out on safety. If no power replace control. 10. Pressure Control Disconnect all power to the controller. Disconnect the wires from the controller. Connect an ohmmeter between the switch terminals. Lower the set point of the controller, the switch should make raise the set point and re-check, switch should break. If the controller operates improperly, replace it. CONTINUED ON NEXT PAGE Page 68

77 TROUBLESHOOTING Troubleshooting Oil boiler Problem Cause Remedy Poor combustion Burner back fires 1. Refractory bricks Check the bricks are not plugged with soot or broken into pieces. Clean and replace as required. 2. Stainless steel ring Check to ensure the ring is present and fits securely against the furnace wall. 3. Main air adjustment Check air adjustment. Open main air until fire brushes the furnace wall. 4. Secondary air adjustment. Check main air adjustment to see if it has moved. Adjust as necessary and tighten in position. Check CO 2 and O 2 level. 5. Draft Check draft is neutral. Consider installing a barometric damper if the draft is too strong. 6. Dirty flue Check flue for Carbon build-up or blockage. Clean flue passages with brush. 7. Negative room pressure Ensure no exhaust fans are running in the boiler room. 8. Oil nozzle Check for blocked nozzle, clean or replace as necessary. 9. Oil pump Check for blocked strainer or filter. Remove or clean. Check for slipping or broken coupling. Tighten or replace. Check for seized pump shaft. Replace. 1. Refractory bricks Check the bricks are not plugged with soot or broken into pieces. Clean and replace as required. 2. Ignition electrodes Check electrodes for carbon build-up, clean if required. Check settings adjust if required. Check for cracks in porcelain, if found, replace. 3. UV detector Check for dirt on scanner, clean as required. Check for proper location of detector. 4. Draft problem Check draft is neutral. Consider installing a barometric damper if the draft is too strong. 5. Negative room pressure Ensure no exhaust fans are running in the boiler room. 6. Primary air adjustment Check air adjustment. Air may be blowing fire away from flame detector. 7. Oil valve(s) Check for leaking oil valve(s) and replace. 8. Loss of oil prime Check all lines for possible air leak in intake line and tighten. Check for possible restricted intake line. Replace. 9. Loose oil fittings Check all fittings and tighten. 10. Blocked oil filter Check and clean or replace. 11. Blocked screen in oil pump Check and clean or replace. 12. Blocked flue Check flue is not blocked, clean as required. Check draft at flue. 13. Vacuum on pump Check for too high a vacuum on the pump. Check oil lines and distance from tank to boiler. Repair or replace as necessary. 14. Hole in suction line Check and replace as necessary. CONTINUED ON NEXT PAGE Page 69

78 TROUBLESHOOTING - 6 Fulton Ltd 6.2 Troubleshooting Oil boiler Problem Cause Remedy Boiler will not maintain pressure 1. Oil tank empty Refill the oil tank. A slight delay in the repriming of the fuel pump may cause the burner programmer to require resetting before the boiler operates satisfactorily. 2. Oil nozzle Check for blocked nozzle. Clean or replace. 3. Oil valve Check voltage between oil valve leads at terminal block to be sure oil valve is getting power. 4. Oil pump Check for blocked strainer or filter. Remove and clean. Check for slipping or broken coupling, tighten or replace. Check for seized pump shaft. Replace the pump. 5. Dirty flue Check flue for Carbon build-up or blockage. Clean flue passages with brush. 6. 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, switch should break. If the controller operates improperly, replace it. 7. Scale build-up in boiler Consult Fulton. 8. Refractory bricks Check the bricks are not plugged with soot, cracked or broken into pieces. Clean and replace as required. 9. Boiler size Boiler may be under sized for the application. Consult Fulton. CONTINUED ON NEXT PAGE Page 70

79 TROUBLESHOOTING Troubleshooting Oil boiler Problem Cause Remedy Boiler is surging 1. Steam traps blowing through. Check traps, clean or replace as required. 2. Scale buildup or lime deposits. Call water treatment company and consult the factory. 3. Too much water treatment Dump the return tank and flush the system. Test the water treatment. 4. Too much of a load. Check total equipment load against the boiler output. Decrease amount of equipment being used. Boiler rumbles 1. Draft problem Check draft is neutral. Consider installing a barometric damper if the draft is too strong. 2. Too much main air. Adjust main air. 3. Air or water in the oil. Check tank and lines for water or leaks. Boiler pushing 1. Steam traps Check traps. Clean or replace as required. steam 2. Too much water treatment. Dump the return tank and flush the system. Test the water treatment. Pump will not cut off Pump runs but does not put water in the boiler Water pump runs intermittently Boiler continues after shut down Oil fumes coming out around the oil pump housing 1. Dirty probes. Clean or replace as required 2. Relay failed. Check relay is secure on its base, if so, replace the relay. 3. Earth connection. Check for tightness and clean. 1. Vapour locking of pump. Allow system to cool down, check steam traps of pump and check to be sure return lines are not insulated. Check return tank temperature, if it is above 82 C vapour locking of the pump will occur. Inspect check valves. Clean and replace as needed. Replace pump with multi-stage centrifugal pump able to cope with 121 C. 2. Blocked feed water line Check feedwater line is not blocked, clean as required. 1. Scale on probes. Check probes, clean as required. 2. Bad pump contactor. Check to ensure the contactor is live. Check to ensure the contactor coil is being pulled in. Replace as required. 3. Pump motor damaged. Check the pump circuit is live. If the circuit is live but the pump is not running, replace the pump. 1. Oil valve defective Check the valve is opening and closing. 1. Bad draft condition Check the draft with a gauge, should read neutral. May need to install a barometric damper. 2. Venting of room Ensure the boiler room doors are closed on shut down and the recommended vents are clear. Boiler flooding 1. Pump does not shut off. Dirty probes, clean or replace as required. 2. Relay failed. Check relay is secure on its base, if so replace the relay. 3. Earth connection. Check for tightness and clean. 4. Vacuum created with the boiler off. As the boiler cools it pulls water from the system. To prevent this, add an anti-vacuum valve on the steam gauge assembly piping, this valve closes under pressure and opens under vacuum. Page 71

80 TROUBLESHOOTING - 6 Fulton Ltd 6.3 TROUBLESHOOTING FEEDWATER pump Problem Cause Remedy 1. FEEDWATER PUMP Pump will not run 2. Motor starter overload, trips out immediately when supply is switched on. 3. Motor contactor overload trips out occasionally. 4. Pump capacity not constant. 5. Pump runs but gives no water. 6. Pump runs backwards when switched off. 7. Leakage in shaft seal. 1. Supply failure. Connect the electricity supply. 2. Fuses/Circuit Breakers are blown. 3. Motor contactor overload has tripped out. Replace fuses/circuit Breakers. Reactivate the motor protection. 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. 1. One fuse/automatic circuit Replace the fuse, reset the circuit breaker. breaker is blown. 2. Contacts in motor contactor Replace motor starter contacts. overload are faulty. 3. Cable connection is loose or Tighten or replace the cable connection. faulty. 4. Motor winding is defective. Replace the motor. 5. Pump blocked. Remove the blockage. 6. Overload setting too low. Set the motor starter correctly. 1. Overload setting is too low. Set the overload correctly. 2. Low voltage at peak times. Check the electricity supply. 1. Pump inlet pressure is too low Check the suction conditions. (cavitation). 2. Suction pipe/pump partly Clean the pump or suction pipe. blocked. 3. Pump draws in air. Check the suction conditions. 1. Suction pipe/pump blocked. Clean the pump or suction pipe. 2. Foot or non-return valve Repair the foot or non-return valve. blocked in 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 Change the direction of rotation of the motor. direction. 6. Boiler feedwater non-return valve letting water passed the valve seat. Check and clean boiler feedwater non-return valve, ensure it is seating (normally and not allowing water passed. accompanied by banging in the feedwater tank). 7. Vapour locking of pump. Allow system to cool down, check steam traps of pump and check to be sure return lines are not insulated. Check return tank temperature, if it is above 82 C vapour locking of the pump will occur. Inspect check valves. Clean and replace as needed. Replace pump with multi-stage centrifugal pump able to cope with 121 C. 1. Leakage in suction pipe. Repair the suction pipe. 2. Foot or non-return valve is Repair the foot or non-return valve. defective. 1. Shaft seal is defective. Replace the shaft seal. CONTINUED ON NEXT PAGE Page 72

81 TROUBLESHOOTING TROUBLESHOOTING FEEDWATER pump Problem Cause Remedy 8. Noise. 1. Cavitation occurs in the pump. Check the suction conditions. 2. Pump does not rotate freely Adjust the pump shaft. (frictional resistance because of incorrect pump shaft position. 3. Frequency converter operation. See Grundfos manual. 4. Boiler feedwater non-return valve letting water passed the valve seat, (normally accompanied by banging in the feedwater tank). Check and clean boiler feedwater non-return valve, ensure it is seating and not allowing water passed. 9. Water pump runs 1. Scale on probes. Check and clean probes, replace as necessary. intermittently 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. 10. 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 off. As the boiler cools, it pulls water from the system piping. To prevent this, add a check valve on the steam gauge assembly piping, which closes under pressure and opens under vacuum. Page 73

82 TROUBLESHOOTING - 6 Fulton Ltd 6.4 Troubleshooting burner control unit-lfl 1 (Siemens) Symptom and identification symbol Cause Remedy 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 start-up sequence 1. Air Damper Check fully open microswitch is made. 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 start-up sequence 1. Air Damper Check low fire microswitch is made. 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 Note: Any flame signal failure after this stage will cause a lockout condition Check flame stability with ignition off. Check air pressure at burner. Check gas pressure is steady. 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. LFL CONTINUED ON NEXT PAGE Page 74

83 TROUBLESHOOTING Troubleshooting burner control unit-lfl 1 (Siemens) Symptom and identification symbol Cause Remedy 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 Lockout 1. Flame failure Check flame signal. 2. Air pressure failure Check switch operation. l Lockout on completion of control programme sequence 1. Extraneous light Check flame extinguished. Check gas valves for leaks. 2. Faulty flame signal Check for aged/faulty UV cell. Check flame supervision circuit. Page 75

84 Page 76

85 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 ( or consult Fulton Ltd. Page 77

86 M APPENDIX - A Fulton Ltd J Series Dimensions & Specification Technical Information Sheet No. 117 Issue 15 Dimensions H R V 360 A L U T E J D N P S X K G W B C MODEL: J SERIES 6J/8J/10J 15J 20J 30J 50J/60J A Minimum Clearance* B Overall Width C Overall Depth D Overall Height E Boiler Height F Boiler Diameter G Height to Top of Fan H Gas Train Length J Gas Inlet Height K Oil Inlet Height L Safety Valve Discharge Height M Steam Outlet Height N Feedwater Inlet Height P Flue Outlet Height R Flue Diameter S Main Boiler Blowdown Height T Control Column Blowdown Height U Water Level Gauge (Sight Glass) Blowdown Height V Water Level Gauge Stand Off W Control Column Stand Off X Fan Stand Off * Recommended height for service & maintenance Note: Dimensions mm Note: Dimensions are approximate and only intended as a guide to aid installation. Basic Strip Down Dimensions 6J/8J/10J 15J 20J 30J 50J/60J Minimum Height (base to top of lifting eye) Boiler Diameter Minimum dimensions for J series boilers for access (boilers with removable fitting i.e. burner scroll, gas train, water level gauges removed). Allowances must be made for handling equipment used. Page 1 of 2 Page 78

87 APPENDIX - A Specification TI-117-J-DS MODEL: J SERIES UNIT 6J 8J 10J 15J 20J 30J 50J 60J CE marked to PED, EMC & LVD, constructed to BS EN as standard (other code specifications available). General Steam Output F & A 100 C kg/h kw Rating kw Operating Pressure ** barg Weight Shipping Weight kg Operational Weight kg Water Content L Efficiencies Gross % Net % Gas Pressures (working) Min. Natural Gas Modulating*** mbar Min. Natural Gas On/Off mbar Max. Natural Gas mbar Min. LPG mbar Max. LPG mbar Firing Rate Gas **** m 3 /h Oil L/h LPG/Propane m 3 /h Ventilation Requirements for Combustion Purposes (Free Area) Low Level inlet cm High Level Outlet cm Electrical Requirements***** FLC 400 V 3 ph 50 Hz A/ph FLC 230 V 1 ph 50 Hz A 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 25 F 25 F Feedwater Inlet DN 20 M 20 M 20 M 20 M 20 M 20 M 20 M 20 M 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 6 weld 6 weld 6 weld 6 weld 6 weld 6 weld 6 weld 6 weld DN (Sight Glass) nipple nipple nipple nipple nipple nipple nipple nipple 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 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. ***** Includes Burner fan motor, feedwater pump & 4A standard control circuit. Note: Electrical enclosures are rated IP20 Page 2 of 2 Fulton Ltd 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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 79

88 APPENDIX - A Fulton Ltd J Series Probe Lengths Technical Information Sheet No. 137 Issue 3 DATUM: underside of probe hex.head (optional) Top of Sockets / Shell / Furnace 1st Low Water 430 2nd Low Water High Water Probe Centre of Glass Pump Off 216 Pump On 241 Note: 350 Sight Glass Probe Lengths - J Series Pump OFF 216 Pump ON 241 1st Low Water 430 2nd Low Water 430 High Water (optional) 216 Note: Dimensions mm Note: Dimensions are approximate and only intended as a guide to aid installation. Page 1 of 1 Fulton Ltd 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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 80

89 APPENDIX - A J Series & Electric Steam Boilers Recommended Water Conditions Technical Information Sheet No. 139 Issue 4! 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 ppm in the form of CaCO 3. Suspended Solids None Chloride Less than 50 ppm. Organic Matter Less than 5 ppm. Oil None Minimum Temperature 85 C BOILER WATER (water inside boiler) ph Value 10.0 to 12.0 tested at room temperature. Hardness Not detectable. Suspended Solids Less than 100 ppm. Chloride Less than 500 ppm. Oxygen Scavenger, Sodium Sulphite 30 to 70 ppm. Tannin 30 to 70 ppm Phosphate 30 to 70 ppm, in the form of PO 4. Total Alkalinity Less than 1000 ppm. Caustic Alkalinity Minimum 300 ppm as CaCO 3. Total Dissolved Solids (TDS) Less than 2000 ppm. Iron Less than 1 ppm. Silica Less than 150 ppm, in the form of SiO 2. Dissolved Oxygen None KEY mg/kg = Milligrams per Kilogram CaCO 3 = Calcium Carbonate PO 4 = Phosphate SiO 2 = Silicon Dioxide PPM = Parts Per Million 1 Grain hardness = ppm therefore 70 ppm = 4.10 grains hardness For practical purposes ppm = mg/kg It is critical that the boiler water ph be alkaline in the range Daily boiler blowdown is essential to help prevent formation of deposits and reduce Total Dissolved Solids (TDS). Consult your water treatment specialist to establish the frequency and duration of blowdown required to achieve the required conditions. Fulton Ltd 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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 81

90 APPENDIX - A Fulton Ltd Water Level Probes Replacement Technical Information Sheet No. 103 Issue 4 Standard Probes (brass) Probes are supplied in a standard length and should be cut to the length required, (the length of the probe being replaced) ensuring measurements are taken from the underside of the probe hexagonal nut, remove any burrs caused by cutting.! 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. 1). 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. 2). 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 PTFE Insulation Probe rod Probe rod grub screw Probe rod lock nut Terminal nut Probe body Figure. 1 - Water Level Probe Components Figure. 2 - Angle Rajah Fitted to Probe Page 1 of 2 Page 82

91 APPENDIX - A High Integrity Probes (stainless steel) TI-103-Water Level Probes The probe is supplied in two parts, the head and the tip. The tip should be screwed onto the head aligning the slot in the top of the tip with the hole in the screwed shaft of the head. Locate the pin provided into the slot/hole and secure with the lock nut. Using the measurement from the old probe, cut the new probe to length and de-burr. Ensure both measurements are taken from the underside of the hex. nut on the probe head. Ensure measurements are taken from the underside of the hex. nut on the probe head. Align the hole in the probe head with the bottom of the slot in the probe tip. Hold the probe head secure whilst fitting the probe tip. Locknut Locate the pin in the hole/slot and secure with the locknut. Figure. 3 - High Integrity Water Level Probe Page 2 of 2 Fulton Ltd 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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 83

92 APPENDIX - A Fulton Ltd Automatic TDS Blowdown Systems Technical Information Sheet No. 30 Issue 4 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 for vertical boilers or 3500 ppm for horizontal boilers), 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. 500 Feedwater TDS at varying condensate return rates Feed water TDS (ppm) Condensate return (%) Raw water TDS (ppm) Figure. 1 - TDS Graph 1 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. Page 1 of 2 Page 84

93 APPENDIX - A TI-30-Auto TDS Blowdown 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. The purchase price of the system supplied fully or part fitted includes for one single visit to commission the system once installed. Part of the commissioning process will be the initial calibration of the TDS sensor to the water conditions prevailing at the time. 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 and staff training required to carry out TDS sampling and calibration can be provided by Fulton. 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. For further details on the installation of Automatic TDS Controlled Blowdown Systems consult the Fulton Ltd Technical Information Sheet 35. Automatic TDS Control Blowdown System Installation Guide Blowdown (as a percentage of boiler output) Feedwater TDS (ppm) From Fig. 1. % Blowdown required to maintain a boiler TDS of 2000ppm against feed water TDS Figure. 2 - 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 120 kg/h (120 l/h) of blowdown is required. Page 2 of 2 Fulton Ltd 5 Fernhurst Road, Fishponds, Bristol. BS5 7FG. England. Telephone: +44 (0) Fax: +44 (0) sales@fulton.co.uk Website: 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 85

94 APPENDIX - A Fulton Ltd Page 86

95 APPENDIX - B APPENDIX B - WIRING DIAGRAMS 1.1 General Wiring diagrams are available from Fulton Ltd on request. Boiler Fuel Controls Arrangement 1 Arrangement 2 Arrangement 3 10J, 15J, 20J, 30J GAS ON/OFF 030JG324O1 030JG324O2 030JG324O3 OIL ON/OFF 030JO324O1 030JO324O2 030JO324O3 30J GAS MOD - 030JG324M2 030JG324M3 40J, 50J, 60J GAS HIGH/LOW 060JG324H1 060JG324H2 060JG324H3 MOD - 060JG324M2 060JG324M3 OIL ON/OFF 060JO324O1 060JO324O2 060JO324O3 DUAL HIGH/LOW 060JD324H1 060JD324H2 060JD324H3 MOD - 060JD324M2 060JD324M3 Page 87

96 APPENDIX - B Fulton Ltd Page 88

97 APPENDIX - C APPENDIX C - SPARE PARTS 1.1 Ordering Spares Note: Spare and wearing parts which have not been tested together with the system can compromise its function. Installing non-authorised components and non-approved modifications/conversion can compromise safety and may invalidate your warranty. For replacements, use only original spare parts from Fulton or those which are approved by Fulton. Using the appropriate information as completed below, order spare parts using the Fulton Spare Parts section in this manual. To order spare parts please contact Fulton spares department at spares@fulton.co.uk or call the Fulton Ltd main number. In order to ensure spare parts are correct, please complete the details below and have them at hand when ordering parts or making enquires regarding the boiler. 1. Boiler serial number: 2. Boiler model and size: 3. Fuel type used: 4. Wiring Diagram No. 5. Commissioning Date:! WARNING The type, size and lift pressure of the safety valve fitted to a boiler is specific to that boiler. When ordering new safety valves it is important that, as well as the information requested above, the following additional information is given: 6. Boiler design pressure (on the boiler data plate) 7. Make and type (eg fig no.) of safety valve fitted. Page 89

98 Page 90

99 APPENDIX - D APPENDIX D - 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 Air Damper Motor Figure 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. Page 91

100 APPENDIX - D 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 Fuel Input Rates Model Low Fire m 3 /h ft 3 /min High Fire m 3 /h ft 3 /min Note: Boilers are pre-commissioned before leaving the factory to ensure optimum gas input rates and combustion values Air Damper Motor CAM I CAM II CAM III CAM IV Figure Air Damper Motor AM Position Typical Degrees I High Fire End Stop 70 II Low End Stop 0 III Low Fire 23 IV High/Low Light 45 Page 92

101 APPENDIX - D Setup Procedure 1. Set the cams on the air damper motor to the initial positions. 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 CO 2 constituent of the flue gases is %. 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 CO 2 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 CO 2 constituent of the flue gases is %. 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 Transformer, ZT Switch, air pressure Air actuator, SQN Fan Coupling, air gate Page 93

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103 APPENDIX - E APPENDIX E - 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 Low WATER DAILY With the burner firing: 1. Press and hold the Low Water test button for 5-6 seconds, the Low Water alarm sounds, Low Water indicator lamp and Low Water Reset switch illuminates, and the burner shuts down. 2. Release the test button. 3. After approximately 17 seconds the Low Water Relay will reset. 4. To cancel the Low Water level alarm and light, depress the Low Water Reset switch. The burner will restart. CONTINUED ON NEXT PAGE Page 95

104 APPENDIX - E Fulton Ltd 1.2 Weekly TEST IN addition Low WATER WEEKLY in addition With the burner firing: 1. Switch the Pump switch to the Pump OFF position. 2. By evaporation, lower the water level in the boiler until the Low Water alarm sounds, the Low Water Reset buttons illuminate, and the burner shuts down. 3. Switch the Pump switch to the 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 Low Water level the Low Water Relay can be reset. 6. To cancel the Low Water Level alarm and light, press the Low Water Reset button. The burner will restart. Page 96

105 APPENDIX - F APPENDIX F - Set Back Control (On/Off or High/Low Control Modes) 1.1 Description The system allows for standard On/Off or High/Low boiler control. It also allows control to setback pressure. The setback control can be automatic (time clock) control, local control via an HMI button or remote control via a switched contact. 1.2 Pressure Settings Use the down cursor key until the operating/setback pressures screens is displayed for the relevant control mode. Figure Setback Controller On/Off Control Screen Figure Setback Controller High/Low Control Screen Page 97

106 APPENDIX - F Fulton Ltd Pressure setting for On/Off control. 1. OP Pres Off Standard operating pressure setpoint, Burner firing stops when actual working pressure reaches or exceeds this pressure. 2. OP Pres On Burner firing restarts when the actual working pressure falls below this pressure. 3. SB OP Off Setback operating pressure setpoint, Burner firing stops when actual working pressure reaches or exceeds this pressure. 4. SB OP On Burner firing restarts when the actual working pressure falls below this pressure. Pressure setting for High/Low control. 1. OP Pres Off Standard operating pressure setpoint, Burner firing stops when actual working pressure reaches or exceeds this pressure. 2. OP Pres On Burner firing restarts when the actual working pressure falls below this pressure. 3. H/L OP Off Operating pressure setpoint when the burner switches to low flame when the actual working pressure reaches or exceeds this pressure. 4. H/L OP On Pressure at which the burner switches back to high flame when actual working pressure falls below this pressure. 5. SB OP Off Setback operating pressure setpoint, Burner firing stops when actual working pressure reaches or exceeds this pressure. 6. SB OP On Burner firing restarts when the actual working pressure falls below this pressure. 7. SB H/L Off Setback operating pressure setpoint when the burner switches to low flame when the actual working pressure reaches or exceeds this pressure. 8. SB H/L On Pressure at which the burner switches back to high flame when actual working pressure falls below this pressure. Check the pressure settings and adjust as required. 1. Press & hold the ESC key for 3 seconds. 2. Use the cursor keys to go to the relevant pressure setting. 3. Press the ENTER key to enable the edit mode. 4. Use the cursor keys to change the pressure setting. 5. Press the ENTER key to save the changes. 6. Use the cursor keys to access the next setting. 7. Use the same procedure as above to edit the remaining pressure settings. Page 98

107 APPENDIX - F 1.3 Automatic (Time Clock) Control Standard/setback mode is controlled by the clock settings. Flexibility of the setback times are available using 3 off setback clock setting screens. Figure Setback Controller Setback Clock Screens Set the required days and times when setback is required. 1. Press & hold the ESC key for 3 seconds 2. The Days will highlight. 3. Press the ENTER key to enable the edit mode. 4. Use the cursor keys to edit the required days. 5. Press the ENTER key to save the changes. 6. Use the cursor keys to access the next setting. 7. Use the same procedure as above to edit the relevant Days, On times & Off times. 1.4 Local Control Operation of the C function key advances the state of operation from standard to setback and vice versa. The state then remains active until the next change of state by the C function key or the time clock. 1.5 Remote Override By connecting a 3 position switch (SETBACK OFF STANDARD) to the relevant input terminals, the setback & standard operation can be controlled from a remote location. When the switch is in the SETBACK or STANDARD position, local control is overridden. With the switch in the OFF position local/clock control is resumed. Page 99

108 APPENDIX - F Fulton Ltd 1.6 Setback Status This screen shows whether the system is being controlled locally or remotely and also its operational state (Standard or Setback). Figure Local Control - Standard Pressure Figure Remote Override - Standard Pressure Figure Local Control - Setback Pressure Figure Remote Override - Setback Pressure 1.7 Boiler Operating Status Screens On/Off control mode and operation mode set to standard. 1. Work Pres Is the actual working pressure of the boiler. 2. Std P Set is the standard operating set pressure. 3. Operate mode Operation mode is set to standard operation. 4. Burner firing Indicates if the boiler is firing Yes/No. 5. Control mode Indicates the boiler control mode. Page 100

109 APPENDIX - F On/Off control mode and operation mode set to setback. 1. Work Pres Is the actual working pressure of the boiler. 2. S/B P Set is the setback operating set pressure. 3. Operate mode Operation mode is set to setback operation. 4. Burner firing Indicates if the boiler is firing Yes/No. 5. Control mode Indicates the boiler control mode. High/Low control mode and operation mode set to standard. 1. Work Pres Is the actual working pressure of the boiler. 2. Std P Set is the standard operating set pressure. 3. Operate mode Operation mode is set to standard operation. 4. Burner firing Indicates if the boiler is firing Yes/No. 5. Flame mode Indicates if the burner is in High flame or Low flame operation. 6. Control mode Indicates the boiler control mode. High/Low control mode and operation mode set to setback 1. Work Pres Is the actual working pressure of the boiler. 2. SB P Set is the setback operating set pressure. 3. Operate mode Operation mode is set to setback operation. 4. Burner firing Indicates if the boiler is firing Yes/No. 5. Flame mode Indicates if the burner is in High flame or Low flame operation. 6. Control mode Indicates the boiler control mode. Page 101

110 1.8 Boiler Operating Hours This screen shows the number of hours that the boiler has operated in standard operation mode and the number of hours the boiler has operated in setback mode. Figure Setback Controller Operating Hours Screen Page 102