INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL 'J' SERIES - GAS FIRED STEAM BOILERS (6J - 60J)

Transcription

1 INSTALLATION, OPERATION, MAINTENANCE AND PARTS MANUAL 'J' SERIES - GAS FIRED STEAM BOILERS (6J - 60J) This Manual must be available to the boiler operator at all times. JGAS-E

2 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, what so ever the cause, then the fuel supply to the boiler should be isolated immediately, until such time that the fault has been investigated by a competent person and rectified. For Your Safety! The following WARNINGS, CAUTIONS and NOTES appear in various sections of this manual. WARNINGS must be observed to prevent serious injury or death to personnel. CAUTIONS must be observed to prevent damage or destruction of equipment or loss of operating effectiveness. NOTES must be observed for essential and effective operating procedures, conditions and as a statement to be highlighted. It is the responsibility and duty of all personnel involved in the operation and maintenance of this equipment to fully understand the WARNINGS, CAUTIONS and NOTES by which hazards are to be eliminated or reduced. Personnel must become familiar with all aspects of safety and equipment prior to operation or maintenance of the equipment. WARNING Steam Boilers are a potential hazard, possibly fatal if not properly maintained. CAUTION It is vitally important that the instructions given in this manual are strictly adhered to. Failure to carry out the routine maintenance checks could result in a drastic reduction in the life expectancy of the boiler. 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.

3 LIST OF CONTENTS TITLE SECTION INTRODUCTION 1 General 1.1 Technical Data (for a full specification refer to section 5) 1.2 INSTALLATION 2 General 2.1 Siting 2.2 Ventilation 2.3 Flue Outlet 2.4 Water Supply (see also Water Treatment in section 5) 2.5 Blowdown Valves 2.6 Main Steam Valve 2.7 Steam Safety valves 2.8 Water Gauge Set 2.9 Gas Supply 2.10 Gas Valve, Pilot Gas (40-60 models & Australia) Electrical Requirements 2.11 Steam Pressure Gauge 2.12 Commissioning the Boiler 2.16 Boiler Inspection and Initial Firing Setting the Burner Controls for Low Fire/High Fire, Models Multibloc Gas Valves 2.17 Cleaning Steam Lines and Pressure Vessel 2.18 Gas Supply - Propane/Butane 2.19 OPERATION 3 General 3.1 Boiler Controls 3.2 Control Panel - Indicator Lights 3.3 Filling the Boiler - All Models 3.4 Starting the Burner - All Models 3.5 Daily Operating Tests 3.6 Pump Check First Low Water Level Check Second Low Water Check Blowdown Procedures 3.7 Evaporation Checks 3.8 Troubleshooting - Boiler 3.9 Troubleshooting - Burner Control Unit LFL Troubleshooting - Burner Control Unit TMG Draining the Boiler 3.12 Long Term Shut Down 3.13 Maintenance Log MAINTENANCE 4 General 4.1 Daily 4.2 Weekly 4.3 Monthly 4.4 Three Monthly 4.5 Six Monthly 4.6 GENERAL DATA 5 Boiler Dimensions Boiler Specification Recommended Water Conditions Probe Lengths Wiring Diagrams Pressure Controller Boiler Controls Test Log

4 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. WARNING It is the responsibility of the installer to ensure all parts supplied with the boiler are fitted in a correct and safe manner. WARNING Do not try to do repairs or any other maintenance work you do not understand. Obtain a Service Manual from Fulton or call a Fulton Service Engineer WARNING Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and or damage. WARNING 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. WARNING The installation of Gas appliances including the flue system should only be carried out by Corgi Registered Enginee WARNING The importance of correct boiler water and feed water cannot be over emphasised, see the relevant section in this manual. WARNING DANGER FROM INCOMPLETE COMBUSTION The importance of correct burner adjustment to achive 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. CAUTION Obey all laws and local regulations which affect you and your boiler. CAUTION LOW FEED WATER TEMPERATURE Low feed water temperature can result in thermal shock to the boiler pressure vessel. Return the maximum amount of condensate and if necessary pre-heat the feed water. If in doubt consult FBW. WARNING Only qualified persons should be allowed to operate and maintain the boiler and its equipment. Boilers should always be drained through an approved Blowdown Vessel. WARNING Do not change the boiler fuel without consulting the boiler manufacturer. WARNING Non-approved modifications can cause injury and damage. Contact your Fulton dealer before modifying the boiler. WARNING LIFTING EQUIPMENT Make sure that lifting equipment complies with all local regulations and is suitable for the jobyou can be injured if you use faulty lifting equipment. Make sure the lifting equipment is in good condition. WARNING 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 up grade the boiler performance by unapproved modifications. WARNING DANGER FROM HOT SURFACES 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. CAUTION HYDRAULIC TEST - RISK OF BRITTLE FRACTURE Hydraulic testing requires specialist equipment and is normally only required by engineering surveyors / inspectors. The material the boiler is manufactured from, has not been impact tested, as it is not a requirement of BS2790 (boiler construction standard). In order to ensure the material / pressure vessel does not suffer from brittle fracture, hydraulic testing should not be carried out below 7 O C. CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants are NOT 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.

5 Optional Variations (where fitted) Motorised High / Low Control Spirax High Integrity Level Controls Automatic TDS Blowdown System Title Appendix B C D Fig. No. Gas Fired Steam Boiler 1 General Arrangement 2 Typical Installation 3 Boiler Flue Connection 4 Boiler Feed Water Arrangement 5 Boiler Blowdown (20-60) 6 Boiler Blowdown (6-15) 7 Water Column Blowdown Valve 8 Water Column Sequencing Valve 8A Boiler Top Components 9 Steam Pressure Gauge 10 Burner Electrode Settings Gas Valve 12 Pressure Controller Gas Valve 14 Gas Valve Detail 15 Control Panel Facias 16 Boiler Blowdown Valve 17 Sequencing Blowdown Valve 18 Water Level Gauges 19 Boiler Maintenance 20 Removing/replacxing UV Detector 21 Handhole 22 Boiler Furnace 23 Ignition Electrode 24 Burner Plate 25 Burner Assembly 26 Flue Cleaning 27 Boiler Dimensions 28 Electrical Circuits Three Phase Supply Circuit 29 Three Phase Supply Circuit - Australian Boilers Only 30 Ancillary Control Circuit 31 Burner Control Circuit 32 Burner Control Circuit, Australian Boilers Only 33 Burner Control Circuit, High - Low Gas 34 PM5 Remote Panel / Typical boiler Connections 35 Tank Solid State Water Level and Alarm Circuits 36 Standard Single Boiler and Ancillary Skid Electrical Connections 37 Spirax Level Control Circuit 38 LC Level Control Circuit 39 TDS and Blowdown Control Circuit 40

6 1 1 Gas Supply Valve Monobloc Gas Valve Supply Gas, Pressure Test Point Steam Pressure Gauge Feed Water Isolating Ball Valve Gas Inlet Feed Water Non-return Valve Scale Trap Steam Supply Valve Safety Valve Water Column containing water level probes Air Pressure Switch Air Intake Manifold containing Main Air Control Sight Gauge Blowdown Valves Boiler Control Panel Water Column Blowdown Valve Control Box Door Lock Feed Water Pump Isolator Switch Boiler Blowdown Valve Control Box Isolator Switch Steam Pressure Control Clean Out Handhole (Water Jacket) Clean Out Door (Gas turn around) FIG.1 GAS FIRED STEAM BOILER 1

7 1 1 INTRODUCTION 1.1 General (Fig. 1) SECTION 1 The J Gas Service Manual is a generic publication, as such provides information on standard boiler operation and maintenance. The Fulton J Series Gas Fired Steam Boiler is a vertical two pass boiler of simple and efficient design and construction. Every care has been taken in the manufacture of the boiler to ensure that quality and reliability standards are maintained. However, 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 - Boiler Output for a full specification refer to Section 5. BOILER MODEL 6J 8J 10J 15J 20J 30J 40J 50J 60J Output kg/h (F & A 100 o C) CAUTION WATER SOFTENER and CHEMICAL TREATMENT The chemicals required to operate the water softeners and chemical treatment plants are NOT 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. 2

8 2 2 Gas Cock Modular Gas Unit Pressure Test Point Steam Pressure Gauge Feed Water Isolating Ball Valve Scale Trap Check Valve Main Steam Valve Steam Safety Valve Air Safety Switch Water Column with water level probes Blower Housing containing Main Air Control Water Gauge Sets Burner Motor Operator Control Panel Blowdown Valve Water Column Blowdown Valve Pressure Control Main Boiler Blowdown Valve Hand Hole (Water Jacket) FIG. 2 GENERAL ARRANGEMENT Clean Out Door (Gas turn around) 3

9 2 2 INSTALLATION 2.1 GENERAL SECTION 2 The installation of a J Series Gas 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 or manufactured gas. Where the boiler is to operate on L.P. Gas, special reference should be made to Section Gas Supply, and Section 2.18 L.P. Gas Supply. 2.2 Siting ( Reference should be made to Utilization 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 large to allow easy and safe access to all parts of the boiler for operational and maintenance purposes. Reference should be made to Section 5 - General Data 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 Note: (a) Ensure there is adequate ventilation in the boiler room. Lack of ventilation will create a high temperature and cause control lockout. (b) (c) Do not keep exhaust fans running with windows, doors and vents closed, this will interfere with the necessary boiler draught. 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 section 5 for Low and High Level values. 4

10 2 2 F03164 Steam Supply Cowl Pipe safety valve to a safe area, using unions and drain as required. Feed water isolation ball valve Feed water non-return valve Standard boiler trim supplied with boiler D H D = Diameter of flue H = 1.5 X D Flue Draught stabiliser (when fitted) Note: A break tank may be required depending upon Local Water Authority By-laws Clean-out door Overflow Make-up feed water supply Flue spigot Flanged connection 20-60J only Condensate return Feed water pump Flexible link Stainless steel feed water and condensate return tank Vent Blowdown Separator Overflow to drain Boiler blowdown valve Drain Strainer Plugged drains Isolating gate/ball valve 5 FIG. 3 TYPICAL INSTALLATION Water column blowdown line

11 Flue Outlet Note: 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 meter 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. 1. If the flue layout is such that it may produce an excessive up-draught, a draught stabiliser may be required. 2. Avoid fitting 90deg. elbows whenever possible, if unavoidable compensate by increasing the flue diameter. 3. Ensure all flue pipes from the boiler to the main flue have a rising pitch. 2.5 Water Supply The quality of the water used in the boiler will affect the life and performance of the boiler. Feed water 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 Section 5 Water Treatment. FIG. 4 BOILER FLUE CONNECTION Isolating Ball Valve Check Valve Connect the feed water pump to the check valve inlet with 25 mm. bore pipe (this may be reduced to 15 mm. where the discharge pipework is shorter than 4m in total), the pump suction pipe work must remain at 25mm minimum diameter.) and insert the stop valve supplied, between the boiler and the check valve. It is essential to protect the feedwater pump from Feed damage by foreign matter, a strainer should Water therefore be fitted in the pump suction pipework Supply Care should be taken to ensure the pipework is properly aligned and not placing any strain upon the feed water pump. Note: FIG. 5 BOILER FEED WATER ARRANGEMENT 1. 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. 2. 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 Boiler Works. 3. The Feedwater inlet connection on some boilers is located on the left hand side of the boiler below the sight glass assembly. 6

12 BOILER Blowdown Valves There are three blowdown valves on the boiler (four if two water gauge sets are fitted), the boiler blowdown valve at the rear of the boiler, the water column blowdown valve and the water gauge blowdown valve. 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 blow down arrangements, consult your Fulton agent. Note: 6J - 15J main blowdown connection via branch pipe 20J - 60J main blowdown connection is integral, via a boiler mounted flange. FIG. 6 BOILER BLOWDOWN (models 20-60) (skid mounted boiler shown) FIG. 7 BOILER BLOWDOWN (models 6-15) (skid mounted boiler shown) 7

13 WATER COLUMN Blowdown Valve The valve on the water column should be operated daily to blowdown the column. Water Column Blowdown Valve FIG. 8 WATER COLUMN BLOWDOWN VALVE WATER COLUMN Blowdown Valve (Australian boilers only). The valve is a three position isolation valve, each position is indicated on a backing plate mounted with the valve, (the valve is shown in the blowdown position). FIG. 8A WATER COLUMN SEQUENCING and BLOWDOWN VALVES (Australian boilers only) 8

14 2 2 Flame (UV) Detector Secondary Air Control Secondary Air Control Main Gas Valve Boiler Water Level Probes Air Proving Switch Water Feed with Stop Valve and Check Valve Gas Train with 360 O rotation Note: Boiler illustrated is fitted with optional Self Monitoring Controls. 9 FIG. 9 BOILER TOP COMPONENTS

15 Main Steam Valve The main steam stop valve should be inserted in the steam line approximately 12in. (305 mm) from the top of the boiler. 2.8 Steam Safety valves Safety Valves are factory fitted and preset, 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 BS806 clause / BSEN :2002 (a) (b) (c) The lift pressure is indicated on the safety valve. (Do not adjust). The safety valve fitted to the boiler is designed to prevent the boiler exceeding it's design pressure. 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. 2.9 Water Gauge Set (The design may vary from that illustrated) Numbers may vary due to individual countries regulations. Boilers are normally supplied with two complete water gauge sets.the water gauge blowdown cock should be connected to the auxiliary blowdown line from the water column blowdown valve in soft copper tubing. The connection to the gauge cock is DN8, 6mm (1/4in. BSP) Gas Supply WARNING Factory fitted safety valves are preset to protect the boiler only and must not be used to protect any other items not capable of accepting boiler pressure. Verify that the burner is suitable for the type of gas being supplied. Ensure 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 which are fitted with pressure regulating governors. A minimum pressure of 7 in. (17.5 mb) water column at the specified flow rate, is required at the gas train for natural gas installations and a minimum pressure of 5 in. (12.5 mb) water column is required at the gas train for manufactured gas installations. If the gas supply is in excess of 100 mbar (6-30) or 200 mbar (40-60) a suitable regulator is required before the main gas valve. Burners arranged for operation on L.P. gas are supplied with gas trains which include a pressure regulating governor. It is essential that the MAXIMUM pressure of the gas at the gas train does not exceed 32 in. (80 mb) water column and does not fall below 20 in. (50 mb) water column. 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 GAS VALVE, with pilot gas line. (Models and Australian boilers). The main gas valve is fitted with a by-pass system (internal or external depending on the model) the by-pass allows pilot pressure to be maintaned whilst the flame is verified. 10

16 Electrical Requirements An individual wiring diagram for the boiler is located on the inside cover of the control box. 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 feed water pump motors arranged for operation on a three phase supply. The power ratings and requirements are given in Technical Data - Section 5. Steam Pressure Gauge Plug Steam Cock Test Point Syphon F03210 FIG. 10 STEAM PRESSURE GAUGE 2.12 Steam Pressure Gauge The steam pressure gauge assembly should be assembled in accordance with Fig. 10 using a suitable sealant on all joints. Screw the assembly into the top of the boiler and connect the copper tube from the pressure controller to the nipple provided on the assembly. The gauge should be facing the electrical control box and/or the boiler operator. 11

17 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: 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. Smoke Test With the flue capped, the drain stabilizer 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 Boiler Works Immediately. Note: Flues that are designed to operate with positive pressure should be tested to the requirements of IGE/UP/10 March BOILER INSPECTION and INITIAL FIRING (a) (b) (c) Ensure 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 column and the boiler shell and record their lengths. Replace any damaged probes. If the burner is fitted with an ultraviolet or solid state detector, remove the detector and check for damage. Remove the burner and check that the electrodes have not been damaged and that their setting corresponds to the appropriate drawing. Check that the burner is the correct type for use with the gas being supplied. Main Gas Supply Ignition Electrode Ultra-Violet Detector 297.4mm Primary Air Blast Tube 12.7mm 3 mm min. 5 mm max. 50.8mm FIG. 11 BURNER ELECTRODE SETTINGS 12

18 2 2 Main Gas Valve Air Pressure Gauge Feed Water Check Valve Safety Valve Flue FIG J MODELS GAS VALVE (d) (e) (f) Ensure that all wiring connections are correct and that all terminal screws are tight. A barometric type draught stabiliser, if fitted in the flue, should be set for a draught of in. to in. ( mb to mb) of water column pressure with the burner off. Open all the valves in the feed water line. Close the isolating valve on the discharge side of the feed water pump. Remove the priming plug from the pump head and slowly fill the pump with water. Replace the priming plug and tighten secuerly. Note the correct rotation of the pump on the motor fan cover. Start the pump and check the direction of rotation. Vent the pump by means of the vent valve in the pump head. At the same time, open the discharge isolating valve a little. Continue to vent the pump. At the same time, open the discharge isolating valve a little more. Close the vent valve when a steady stream of water runs out of it. Completly open the discharge isolating valve. The bypass valve located in the drain plug may be opened during the filling procedure, close the bypass when the operation is stable. DO NOT ALLOW THE PUMP TO RUN DRY. 13

19 2 2 (g) Open all the valves in the water feed line. Switch on the feedwater pump motor and fill 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 sight level gauge is reading two thirds full, the pump will stop. 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. Close the boiler blowdown valve. For models with an external pilot gas line, see (h) After purging the gas lines of air, start the burner. Note: For Australian boilers only: 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. (j) (k) (l) (m) (n) Check the Satronic burner control for a minimum of four indicator lights to verify the flame. Adjust the gas input by reading the gas meter (if fitted). Adjust the 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, record the results. See typical combustion values in section 5. Observe the flame through the peephole between the electrodes and adjust the scondary air control located on the top of the boiler, so that the flame cannot be seen 'backing up' the blast tube. Check the operation of the low water safety controls. Adjust the steam pressure control to suit the boiler application. 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. If the pressure control is fitted with a differential scale: (see OEM literature in section 5) (i) (ii) Set the main scale pressure to the maximum pressure required (system pressure). Do not exceed the boiler operating pressure. 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. Note: When multiple boilers are fitted with a sequence control: (i) Set the main scale and differential scale as above. FIG. 13 PRESSURE CONTROLLER 14

20 2 2 Main Gas Valve Assembly Main Gas Line Isolating Pilot Line Ball Valve Pilot Line Governor Pilot Line Gas Valves Note: Australian Models are fitted with a Gas Valve Closed Indicator on the Main Gas Valve FIG J MODELS GAS VALVE 15

21 2 2 (ii) Set the setback pressure control to the required set back pressure SETTING THE BURNER CONTROLS FOR LOW FIRE / HIGH FIRE, MODELS The correct setting for low fire/high fire operation are made by making adjustments to the two stage solenoid valve and the low fire steam pressure switch. (a) (b) (c) (d) (e) (f) (g) (h) Isolate the main gas valve by closing the valve in the gas input line. Screw the pilot gas governor fully down, (governor open). Start the burner and where possible meter the pilot gas rate, (ideally the pilot gas rate should be 10% of the full gas rate). Check the LED display on the Satronic control box (where fitted). The pilot should produce a solid line of five illuminated LED's (four minimum). Check the ignition and pilot stability several times. Record the pilot gas pressure. Open the main gas isolating valve. 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. Adjust the low fire steam pressure switch to cut-out at approximately 5 psi below the setting of the main steam pressure control. Adjust the two-stage solenoid valve to obtain a low fire gas input of approximately 80% of high fire. Leave the air gates adjustments as for high fire. 16

22 GAS MULTIBLOCS (see attached manufacturers leaflets). BOILER SIZE MULTIBLOC USED Dungs: 6-30 MB-D(LE) B Australian MB-D(LE) B MB-ZRD(LE) B01 L.P.G. Main gas flow adjustment Hydraulic brake MB-ZRD(LE) BO1 Output pressure controller adjusting screw 6-30 Models Operating indicator Adjustable pressure switch Test point connection Test point connection downstream of valve 1 Gas input filter cover Gas output flange Test point connection downstream of valve 2 Test point connection upstream of valve 1 Output pressure controller adjusting screw Hydraulic brake Operating indicator Main gas flow adjustment Adjustable pressure switch Test point connection downstream of valve 1 Gas input flange Test point connection downstream of valve 2 Test point connection upstream of valve 1 17 Gas input filter cover FIG. 15 GAS VALVE - MAJOR COMPONENTS

23 GAS MULTIBLOCS (continued) Models (with pilot line fitted for Australia) Main Gas Flow Adjustment Hydraulic Brake Output Pressure Controller Adjusting Screw High Fire Solenoid Operating Pressure Indicators Low Fire Flow Adjustment Input Gas Test Point Adjustable Pressure Switch Test Point 1 Downstream (internal leak test) Test Point 2 Downstream Gas Input Mounting Flange Test Point 1 Upstream 18

24 CLEANING STEAM LINES AND PRESSURE VESSEL During the first week of boiler operation, clean all oil and dirt from the boiler, steam line and condensate return line. (a) (b) (c) (d) (e) Disconnect the condensate return pipe adjacent to the condensate return tank. Direct the returns to a floor drain or other safe discharge point and make safe. Leave in this position for one week to allow all impurities to flush through. Drain the boiler completely each day. 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 GAS SUPPLY - PROPANE / BUTANE L.P. GAS WARNING Do not change the boiler fuel without consulting the boiler manufacturer. Note: LPG Boilers should be installed to the requirements of IGE/UP/10 March 2001 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 30 in. (80 mbar) Water Column or less. For PROPANE:-The boiler governor must be adjusted to give a firing pressure of 10 in. (25 mb) water column 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 8 in. (20 mb) water column 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. 19

25 GENERAL SECTION 3 OPERATION The following instructions are given for the guidance of the operator in the use of the J Series gas fired 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. 3.2 BOILER CONTROLS The following brief description of the controls used on the J Series gas fired 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. Note: All the controls are of the fail-safe type and are wired in series; failure of any one will automatically shut down the boiler. Low Water Relays and Feedwater Pump Relays. These relays operate in conjunction with probes suspended in the boiler and water column 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. Steam Pressure Control(s). Located on the control panel box and connected to the steam pressure gauge assembly by copper tube, the pressure regulator controls the on/off cycle of the burner, shutting the burner off when maximum pressure is reached and switching it on when the steam pressure falls. 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 multibloc 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 multibloc incorporating an integral governor, pressure switch and gas valves or for larger boilers in addition to the internal components, an external pilot line with it's own gas proving valves and governor. PUMP CONTROL Pump Interrupt/Pump Run Switch. Fitted on the left side of the control panel, used to override (switch off) the pump controls during evaporation tests. Australian Boilers only. Pilot Hold/Normal switch, Mounted on the right hand side of the boiler control box, the switch is used to hold the main gas valve at pilot pressure in order to verify the pilot flame. 20

26 3 3 6J - 30J 40J - 60J Standard and Australian (standard boilers have the CPI indicator blanked) 6J - 30J Australia 3.2 BOILER CONTROLS continued. Note: Boilers fitted on skid units and in plant rooms are interlocked with the feed water 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. 21 FIG. 16 CONTROL PANEL FACIAS

27 INDICATOR LIGHTS 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 control circuit live light is dirived 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. Start/Low Water Reset. This switch is used to start the boiler and to reset the low water alarm. When the switch is pressed to initiate the start-up sequence, the low water alarm lamp also illuminates and the low water audible alarm sounds. Keeping the switch depressed for approximately 2 seconds cancels the low water alarm and initiates the burner start sequence. Illumination of this switch and sounding of the audible alarm at any other time other than at switch on indicates that the boiler has gone to a lock-out due to a low water condition. Once the water in the boiler has been restored to a safe operating level, pressing the switch will reset the controls. Circuit On. (Circuit Energised 40J - 60J) Indicates that power is being supplied to the control panel box. Low Water Alarm (1st. low water). This light will energise, when the boiler is switched on and the water level is between 1st. low water and 2nd. low water. A light will illuminate and a pulsing alarm sound. Low Water Reset (2nd low water). The 1st. low water light and alarm are replaced by the 2nd. low water light and a continuous alarm, indicated by the low water reset switch. The second alarm must be reset, the first alarm will be automatically reset by the return to normal water level. Ignition. Indicates that the ignition transformer has been energised. This light will only be illuminated for approximately 5-10 seconds during the ignition sequence. Gas Pressure Alarm. 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. Start Gas. (40-60 models and Australian boilers) This light indicates the gas valves in the pilot line are energised. Main Gas. This light illuminates when the Multibloc gas valve is energised. Flame Failure / Reset. This switch will be illuminated when the burner has gone to a lock out condition due to flame failure. The burner controller can be reset by pressing this switch. Combustion Air. This light indicates that the burner motor contactor is energised. Closed Position Indicator (C.P.I.). (Australian Boilers Only) The lamp illuminates when the gas valve is in the closed (no gas) position. ADDITIONAL INDICATOR LIGHTS ON MODELS 40J AND 60J 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. 22

28 FILLING the boiler - All Models Carry out the following procedure on the initial start up of the boiler and on every subsequent occasion when restarting the boiler after a shut down: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) Ensure the main steam stop valve is OPEN. Ensure the steam pressure gauge isolating valve is OPEN. Ensure all the valves in the main gas supply to the boiler are OPEN. Ensure all the valves in the water feed line are OPEN. Ensure the main boiler blowdown valve is CLOSED. Ensure water level gauge isolating valve(s) is OPEN. Ensure water level gauge blowdown valve(s) is CLOSED. Ensure water column blowdown valve is CLOSED. Ensure the Burner and Pump switch is in the OFF position. Ensure all appropriate electrical isolators are switched ON. Ensure the pump interrupt switch is switched OFF (Pump Run). 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. (l) Press the control switch to the PUMP ONLY position. Note: If the boiler water level is below its correct level, the feed water pump will operate. When the water reaches the correct level (two thirds up the water level gauge sight glass), the pump will stop. If the water level is above the top of the water level gauge sight glass, drain off until the level is in the middle of the water level gauge sight glass. 23

29 STARTING THE BURNER (a) (b) (c) (d) (e) CLOSE the main steam stop valve. Press the control switch to 'PUMP AND BOILER' position, the low water audible alarm will sound, the low water reset and low water alarm lights will illuminate. Press the low water reset switch for two seconds maximum. The alarms will stop, and the alarm lights extinguish. The burner start sequence will commence. After a maximum of one minute the burner should be firing, and the main gas light ON. When the boiler has achived the required (set) pressure, the main steam isolating valve should be slowly opened allowing steam to enter the system distribution pipework. WARNING The system should be raised to temperature slowly to allow for expansion and to avoid thermal shock and water hammer. This can be achived by one of two methods. 1. Crack open the main steam valve and allow the system to heat up slowly, (minimum 15 minuets) before fully opening the main steam valve. 2. 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 achived. Note: TDS Panel Mounted Controllers (BC BC3200) if fitted. The controller must be reset after any break in electrical supply to the unit. 3.6 Daily OPERATING TESTS ( ) Visually inspect the steam and feed water pipework, valves and fittings for signs of leakage. If leaks are suspected shut the system down and evacuate the system to atmospheric pressure before attempting to repair the leaks. The following procedure should be carried out by a competent person to ensure the correct functioning of the water level and low water safety controls. Where possible, the boiler should not be under steam pressure during these tests, (see g.2.). 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 Pump check With the burner firing and the pump not running, lower the water level in the boiler by opening the main boiler blowdown valve. As the water level falls, visible in the sight glass, and before the low water lock out position is reached the water pump should start to run. When this happens close the main boiler blowdown valve. The water pump should continue to run and re-fill the boiler to the correct level and stop. 24

30 First Low Water Level (a) Ensure the following: The burner is firing. The water level is correct in the boiler. The water pump is not running. (b) (c) (d) Switch the pump off (Pump Interrupt) at the pump interrupt/pump run switch. OPEN the main blowdown valve. When the water level nears the bottom of the water level gauge sight glass, the low water alarm should sound, the LOW WATER ALARM lamp should illuminate and the burner should stop firing. When this happens, CLOSE the blowdown valve IMMEDIATELY. (e) Switch the pump to RUN at the main pump interrupt/pump run switch. The pump should run and refill the boiler. When the water level in the boiler rises above the first low water level, the LOW WATER LEVEL lamp should extinguish, the audible alarm should silence and the burner start sequence should commence automatically. The pump should run until the boiler water level is correct and then stop Overriding (2nd) Low Water Check (a) Ensure the following: The burner is firing. The water level is correct in the boiler. The water pump is not running. (b) (c) (d) (e) (f) (g) Switch the pump off (Pump Interrupt) at the pump intrrupt / pump run switch. OPEN the main blowdown valve. When the water level nears the bottom of the water level gauge sight glass, the LOW WATER ALARM lamp should illuminate, the low water audible alarm should sound and the burner should stop firing. Continue to blow down the boiler. As the water level falls nearer the bottom of the water level gauge sight glass, the LOW WATER RESET switch should illuminate and the second audible low water alarm should sound. CLOSE the main blowdown valve and switch the pump to RUN at the pump interrupt/pump run switch. The water pump should now start to run and refill the boiler. Once filled to the correct level the pump should stop. The low water alarm should continue to sound, the LOW WATER RESET switch and LOW WATER ALARM lamp should remain illuminated and the burner should NOT start. When the water level in the boiler is correct, the burner can be restarted by depressing the LOW WATER RESET switch for a maximum of 2 seconds. 1. The First and Overriding low water checks can be carried out in one operation to reduce the blowdown time and possible interruption to the steam supply. 2. Where the water level tests are to be carried out at full pressure, evaporate the water down to 1st. low level as in 3.8, blowdown the boiler from 1st. to 2nd. low water. The purpose of adopting this procedure is to prevent steam and water being expelled from the blowdown vessel vent because of prolonged blowdown. 25

31 BLOWDOWN PROCEDURES (DAILY TESTS) Keep the boiler, water gauge, water column and interconnecting pipework free from sludge and scale buildup by blowing down in the following manner: Note: Where a boiler is operating continuously at steam pressure, advice should be sort from Fulton regarding the appropriate blowdown procedure. (a) (b) Start the boiler and generate not more than 10psi of steam. Shut off both the burner and the pump. Boiler Blowdown (a) Fully OPEN the boiler main blowdown valve for not more than 10 seconds. (b) CLOSE the valve. Water Column Note: Where high levels of suspended solids are produced, Blowdown Valve longer and/or more frequent blowdown may be required. Water Column Blowdown Note: The water column contains the pump on/off probe, which is not safety interlocked. (a) OPEN the ball valve in the water column, close after 5 seconds. Australian Boilers only Water Column Blowdown 1. Place the sequence valve lever into the blowdown column position A. 2. Open the Column blowdown valve B for 5 seconds then CLOSE. A 3. Place the sequence valve lever into the blowdown leg position C. D 4. Open the Column blowdown valve B for 5 seconds then CLOSE. C 5. Return the sequene lever to the working B A B/DOWN COLUMN Operating handle shown in the closed position. C B/DOWN LEG D WORKING POSITION Fig. 17 BOILER BLOWDOWN VALVE Fig. 18 SEQUENCING BLOWDOWN VALVE 26

32 3 3 Water Gauge Blowdown (a) Blowdown the water gauge, set Open the 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 Water Level Gauge Set 2 On completion of the blowdown procedure ensure that all isolation valves are OPEN and all blowdown valves CLOSED. Note: Where a Boiler is operating continuously at steam pressure, advice should be taken from a Fulton agent as to the appropriate blowdown procedure. B WORKING POSITION STEAM BLOWDOWN WATER BLOWDOWN B B B C C C C A A A Water Level Gauge Operating Positions A Water Level Gauge Set EVAPORATION CHECKS FIG. 19 WATER LEVEL GAUGES With the boiler running under normal load conditions, and the pump stopped having just completed a refill cycle: (a) (b) Ensure that the boiler water level is correct. Switch the pump off at the pump interrupt / pump run switch. The water level in the boiler will lower through natural evaporation. When the level nears the bottom of the water level gauge sight glass, the first low water alarm will sound, the LOW WATER ALARM lamp will illuminate and the burner will shut down. If it is required to check the second low water alarm, wait a further period for the LOW WATER RESET switch to illuminate. When the check is complete, proceed as follows: (a) (b) Switch the pump to RUN at the pump interruptpump run switch. Press the LOW WATER RESET switch. The pump will start to refill the boiler. If the pump starts to run at any time during the test then the test must be abandoned and re-started from the beginning. 27