FULTON J Series Manuale utente
This manual must be available to the boiler operator at all times. JGASUK-IOMM-2015-2
INSTALLATION, OPERATIONAND MAINTENANCE MANUAL
J Series (UK)
Gas Fired Steam Boiler
(including optional fully modulating burner)
JGASUK-IOMM-2015-2
Fulton Ltd
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JGASUK-IOMM-2015-2
Fulton Ltd
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TABLE OF CONTENTS
SECTION 1 - INTRODUCTION
1.1 General 1
1.2 Technical Data 1
SECTION 2 - INSTALLATION
2.1 General 3
2.2 Siting 3
2.3 Ventilation 4
2.4 Flue Outlet 4
2.5 Water Supply 6
2.6 Blowdown Valve 7
2.7 Main Steam Valve 8
2.8 Steam Safety Valves 8
2.9 Water Level Gauge Set (sight glass) 8
2.10 Gas Supply 8
2.10.1 Gas Valve with Pilot Gas Line 9
2.11 Electrical Requirements 9
2.12 Steam Pressure Gauge 9
2.13 Commissioning the Boiler 11
2.13.1 Boiler Inspection and Initial Firing 11
2.13.2 SettingBurnerControls-low/highre(40J-60J) 14
2.13.3 SettingBurnerControls-fullymodulating(30J-60J) 14
2.14 Multi Bloc Gas Valves 15
2.15 Cleaning Steam Lines and Pressure Vessels 18
SECTION 3 - OPERATION
3.1 General 19
3.2 Boiler Controls 19
3.3 Indicator Lights 21
3.4 Filling the Boiler-all models 22
3.5 Starting the Burner-all models 23
SECTION 4 - MAINTENANCE
4.1 Visual Checks 25
4.2 Water Level and Low Water Safety Controls 25
4.2.1 Pump Test 25
4.2.2 1st Low Water Level Check 26
4.2.3 2nd Low Water Level Check 27
4.3 Main Blowdown 28
4.4 Water Column Blowdown 28
4.5 Water Level Gauge Blowdown 29
4.6 Evaporation Checks 30
4.7 Flame Sensor Test 30
4.8 Draining the Boiler 31
4.9 Long Term Shut Down 32
4.10 Internal Inspection 32
4.11 Schedule of Operator Tests and Checks 33
4.11.1 Daily 34
4.11.2 Weekly-in addition 34
4.11.3 Monthly-in addition 34
4.11.4 Three Monthly-in addition 35
4.11.5 Six Monthly-in addition 35
4.11.6 Annually-in addition 37
4.12.1 Troubleshooting-boiler 38
4.12.2 Troubleshooting-feedwater pump 41
4.12.3 Troubleshooting-burner control unit-LFL1 43
4.13 Maintenance Log 45
APPENDIX A - TI SHEETS
APPENDIX B - WATER LEVEL PROBE INFO
APPENDIX C - MOTORISED HIGH/LOW CONTROL
1.1 General 57
1.2 Operation 57
1.3 Additional Controls 58
1.4 Commissioning 58
1.4.1 Fuel Input Rates 58
1.4.2 Air Damper Motor - Factory Cam Settings 58
1.4.3 Setup Procedure 59
1.5 Spare Parts 59
APPENDIX D - SPIRAX HIGH INTEGRITY LEVEL
CONTROLS
1.1 Daily Tests 61
1.1.1 1st Low Water-daily 61
1.1.2 2nd Low Water-daily 61
1.2 Weekly Test-in addition 62
1.2.1 1st Low Water-weekly in addition 62
1.2.2 2nd Low Water-weekly in addition 62
APPENDIX E - AUTOMATIC TDS BLOWDOWN
SYSTEM
1.1 General 63
Electrical diagrams supplied separately
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WARNINGS
The Pressure System Safety Regulations 2000
Fulton boilers fall within the scope of the Pressure Systems Examination Scheme.
Regular inspections are therefore required by a competent person.
The scope of the examination and the actual intervals between examinations is at the discretion of the competent
person.
It is the responsibility of the user to provide a written scheme of examination for those parts of the system in which
a defect may give rise to danger.
Instructions in this manual are provided for the safe operation and maintenance of the boiler and do not cover
periodic statutory inspections.
For further information contact:
(a) SAFed
SAFETYASSESSMENT FEDERATION Limited.
Nutmeg House,
60 Gainsford Street,
Butlers Wharf,
London, SE1 2NY.
(b) HealthandSafetyExecutivelocalofce.
(c) Your Competent Person.
For your safety!
The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual.
• WARNINGS must be observed to prevent serious
injury or death to personnel.
• CAUTIONS must be observed to prevent damage
or destruction of equipment or loss of operating
effectiveness.
• Notes: must be observed for essential and
effective operating procedures, conditions and as
a statement to be highlighted.
It is the responsibility and duty of all personnel involved
in the operation and maintenance of this equipment
to fully understand the WARNINGS, CAUTIONS and
NOTES by which hazards are to be eliminated or
reduced.
Personnel must become familiar with all aspects of
safety and equipment prior to operation or
maintenance of the equipment.
CAUTION
In case of emergency
This boiler has been designed and constructed to meet all of the essential requirements of the applicable
European Directives and subject to proper maintenance should not give occasion to any hazardous conditions.
If such a condition should occur during commissioning or during subsequent operation of this product,
whatever the cause, then the fuel supply to the boiler should be isolated immediately, until the fault has been
investigatedbyacompetentpersonandrectied.
!
WARNING
Steam boilers are a potential hazard, possibly fatal if not properly maintained.
CAUTION
It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry
out the routine maintenance checks could result in a drastic reduction in the life expectancy of the
system and increase the possibility of re, explosion, property damage, personal injury or loss of life.
!
!
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WARNINGS
SAFETY
The instructions provided for the operation and maintenance of the boiler MUST be observed. Failure to do so could result in
damage to the heater and serious personal injury.
!
WARNING
Do not try to do repairs or any other maintenance work
you do not understand. Obtain a service manual from
Fulton Ltd or call a Fulton service engineer.
It is the responsibility of the installer to ensure all parts
suppliedwiththeboilerarettedinacorrectandsafe
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
performancebyunapprovedmodications.
Non-approvedmodicationscancauseinjuryand
damage. Contact your Fulton dealer before modifying
the boiler.
Only qualied persons should be allowed to
operate and maintain the boiler and its equipment.
Boilers should always be drained through an approved
blowdown vessel.
The installation of gas appliances including the
uesystemshouldonlybecarriedoutbyGasSafe
registered engineers.
Steam boilers have high temperature surfaces, that if
touched may cause serious burns. Only competent and
qualiedpersonnelshouldworkonorinthelocalityof
a steam boiler and ancillary equipment. Always ensure
theworkingareaandoorareclearofpotentialhazards,
work slowly and methodically.
DoNOTstoreinammablematerialsneartheboiler.
The importance of correct boiler water and feedwater
cannot be over emphasised, see the relevant section in
this manual.
!
CAUTION
Obey all laws and local regulations which affect you and
your boiler.
LOW FEEDWATER TEMPERATURE
Low feedwater temperature can result in thermal shock
to the boiler pressure vessel. Return the maximum
amount of condensate and if necessary preheat the
feedwater. If in doubt consult Fulton Ltd.
WATER SOFTENER and CHEMICAL TREATMENT
The chemicals required to operate the water softeners
and chemical treatment plants CAN BE SUPPLIED by
Fulton Ltd.
It is the responsibility of the operator to ensure adequate
supplies of chemical are available at all times
(including commissioning). Costly repairs could be
required should the plant operate without chemicals or
the wrong dosage of chemicals.
HYDRAULIC TEST - RISK OF BRITTLE FRACTURE
Hydraulic testing requires specialist equipment and
is normally only required by engineering surveyors /
inspectors. In order to ensure the material/ pressure
vessel does not suffer from brittle fracture, hydraulic
testing should not be carried out below 7 °C.
!
WARNING
DANGER FROM INCOMPLETE COMBUSTION
The importance of correct burner adjustment to achieve
lowemissions,safe,cleanandefcientcombustion
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
byre-burningoftheunburntgasinthesecondaryue
passes.
Prior to the commencement of any work requiring the
removal of cover plates and the opening of control panel
box, the electrical supply to the boiler must be isolated.
!
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Fulton Ltd
Page VI
Figure. 1 - Non-Modulating Gas Fired Steam Boiler
Monobloc gas valve
Low water level probes
Water column containing
water level probes
Water column
blowdown valve
Water level gauge
(sight glass)
Water level gauge
blowdown valves
Steam pressure limiter
Clean out handhole
(water jacket)
Steam pressure control
Pressure gauge
Air pressure
switch
Air intake
Boiler control
panel
Control box
door lock
Control box
isolator switch
Clean out door
(furnace)
JGASUK-IOMM-2015-2
Fulton Ltd
Page 1
INTRODUCTION - 1
SECTION 1 - INTRODUCTION
1.1 GENERAL
TheFultonJSeriesgasredsteamboilerservicemanualisagenericpublication,providing
informationonstandardboileroperationandmaintenance.TheJSeriesgasredsteamboileris
averticaltwo-passboilerofsimple,efcientdesignandconstruction.
Every care has been taken in the manufacture of the boiler to ensure that quality and reliability
standards are maintained. Satisfactory performance can only be ensured if the installation
recommendations, operating routines and maintenance schedules laid out in this manual are
adhered to.
1.2 TECHNICAL DATA
ForafullspecicationrefertoAppendix A - TI-117-J Series Dimensions & Specication.
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.
!
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Fulton Ltd
Page 2
Figure. 2 - Fully Modulating Gas Fired Steam Boiler
Steam pressure
limiter
Clean out handhole
(water jacket)
Pressure transducer
Air intake
containing main air
control
Boiler control panel
Control box
door lock
Control box isolator
switch
Clean out door
(furnace)
AZL burner control
RWF40
PID Controller
BT1050
Boiler blowdown
timer(iftted)
BC3150
Blowdown controller
(iftted)
LC3050
Level limiters
(iftted)
Low water level
probes
Water column
containing water
level probes
Water column
blowdown valve
Water level gauge
(sight glass)
Water level gauge
blowdown valves
Pressure gauge
Air pressure
switch
JGASUK-IOMM-2015-2
Fulton Ltd
Page 3
INSTALLATION - 2
2.1 GENERAL
TheinstallationofaJSeriesgasredsteamboilershouldbecarriedoutbycompetentpersonnel
in accordance with all relevant safety regulations. It is the responsibility of the installer to ensure
that these regulations are complied with.
The requirements and instructions contained in this section generally relate to the boilers being
installed to operate on natural or manufactured gas. Where the boiler is to operate on L.P. Gas,
special reference should be made to Section 2.10 - Gas Supply, and Section 2.16 L.P. Gas
Supply.
2.2 SITING
(Reference should be made to Utilisation Procedures as stated in IGE/UP/10 Part 1
Communication 1676, and in particular to Section 5, Location of Appliances).
Theboilerhouseshouldbesufcientlysizedtoalloweasyandsafeaccesstoallpartsofthe
boiler for operational and maintenance purposes.
Reference should be made to Appendix A - TI-117-J Series Dimensions & Specication to
ascertain the relevant dimensions and weights, special note should be taken of the required
vertical clearance required for maintenance.
WARNING
Maintenance on the burner assembly requires the area directly above and to one side of the boiler must
not be obstructed with pipework or equipment which would interfere with the removal of the complete
burner unit. Care should be taken on installation of the boiler to ensure this area remains clear of
obstructions.
!
SECTION 2 - INSTALLATION
Theooringmustbelevel,laidinanon-combustiblematerialandbeofsufcientstrengthto
support the boiler.
JGASUK-IOMM-2015-2
Fulton Ltd
Page 4
INSTALLATION - 2
2.4 FLUE OUTLET
2.3 VENTILATION
Adequatefresh,cleanairisnecessaryforsafeandefcientcombustion,andshouldbeprovided
at high and low level in accordance with BS 6644 1991 and IGE/UP/10 Part 1 Communication
1676.
Note: Ensure that there is adequate ventilation in the boiler room. Lack of ventilation will create a high
temperature and cause control lockout. There is a minimum ventilation requirement to supply the air for
combustion.
Note: Do not keep exhaust fans running with windows, doors and vents closed, this will interfere with the
necessary boiler draught.
Note: Do not store chemicals such as perclorethylene in the boiler house, the fumes may damage the boiler and
ue and cause the burner to lock out on ame failure.
Note: see Appendix A - TI-117-J Series Dimensions & Specication for low and high level values.
Theboilerissuppliedwithastainlesssteeluespigotthatshouldbeinsertedintotheueoutlet
in the back of the boiler and secured with the three angle clips supplied loose in the trim box. The
heightandtypeofuewillbesubjecttolocalplanningregulationsandapprovals.
The following information is only intended to provide assistance for the installation of a simple
ue.Wheremulti-boileruesordifcultiesareexperienced,specialistadviceshouldbeobtained.
Theuediametermustbethesameorlargerthantheueangeprovidedwiththeboilerandthe
outlet should be at least 1 metre higher than the nearest ridge to avoid down draughts. Where a
chimneycowlistted,careshouldbetakentoensurethatthedistancebetweenthelowestpoint
ofthecowlandthetopoftheueis1.5xthediameteroftheueandthatitisoftheterminal
cone type.
Note: If the ue layout is such that it may produce an excessive up-draught, a draught stabiliser may be required.
Note: Avoid tting 90° elbows whenever possible, if unavoidable compensate by increasing the ue diameter.
Note: Ensure all ue pipes from the boiler to the main ue have a rising pitch.
Figure. 3 - Boiler Flue Connection
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